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Summary of Contents for KÖCO ELOTOP+ 13 Racoon
- Page 1 Original instructions KÖCO stud welding machine ELOTOP 13 Racoon ELOTOP 22 Fox ELOTOP 25 Tiger ELOTOP 25 Grizzly These instructions are identified by part number 399-0432-000.
- Page 2 All rights reserved This document is to be used by the addressee only for the intended purpose. To duplicate it in part or completely or to translate it into another language without previous written permission is prohibited. The right to undertake technical changes is reserved. ©...
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Page 3: Table Of Contents
ELOTOP Table of contents Using the instructions .......................... 5 Signal words ................................6 Symbols ..................................6 1.2.1 Prohibition symbols ........................6 1.2.2 Danger symbols ..........................6 1.2.3 Information symbols ........................7 Safety information ..........................8 Intended use ................................8 Reasonably foreseeable misuse ........................8 Personal protective equipment ........................9 General safety instructions .........................10 Safety instructions for operation ...................... - Page 4 ELOTOP Faults and malfunctions ........................59 Fault messages and troubleshooting ....................60 Errors without display and error rectification ................64 Results of the process data analysis ....................65 Results of the Process Control (BSPK) ....................68 Maintenance, cleaning and calibration ..................74 Maintenance and cleaning ........................75 Calibration ................................
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Page 5: Using The Instructions
1 Using the instructions ELOTOP Using the instructions The KÖCO ELOTOP stud welding machine was developed according to the rules of technology by Köster & Co. GmbH and complies with the technical rules and regulations valid at the time of delivery. The instructi- ons for the stud welding machine contain all the information needed for the safe use of the device. -
Page 6: Signal Words
ELOTOP 1 Using the instructions Signal words Danger indicates a hazard which, if not avoided, results in death or serious injury. Warning indicates a hazard which, if not avoided, could result in death or serious injury. Caution indicates a hazard which, if not avoided, could result in a minor or mode- rate injury. -
Page 7: Information Symbols
1 Using the instructions ELOTOP Warning of intense arc light! This symbol indicates a risk of injury from arc light. Warning of electromagnetic fields! This symbol indicates hazards due to electromagnetic fields. Warning of obstacles on the ground! This symbol indicates dangerous situations with a trip hazard. 1.2.3 Information symbols Wear protective clothing... -
Page 8: Safety Information
ELOTOP 2 Safety information Safety information Intended use The device is exclusively intended for drawn arc stud welding. It is suitable for welding under increased electrical hazard (DIN EN 60974-1). Any use other than the intended use is regarded as reasonably foreseeable misuse. The manufacturer does not accept any liability for the suitability of materi- als for welding or the suitability of stud welding for applications that are not covered by the intended use. -
Page 9: Personal Protective Equipment
2 Safety information ELOTOP Personal protective equipment Wear your personal protective equipment for all activities on the device. It includes: dry, insulated footwear close-fitting and non-flammable work clothes (e.g. leather apron) that are dry, i.e. free of flammable substances leather gloves ... -
Page 10: General Safety Instructions
ELOTOP 2 Safety information General safety instructions Mains connection Always use a suitable mains plug of the correct size when connecting to the mains. Have a qualified electrician install the mains plug (if it is not supplied or in the case of replacement). -
Page 11: Safety Instructions For Operation
2 Safety information ELOTOP Accident prevention In addition to the safety measures described in these instructions, the company safety regulations and the applicable accident prevention regulations of the employer must be observed. Safety instructions for operation Weld spatter can ignite flammable objects several metres away, e.g. ... -
Page 12: Personnel Qualifications
ELOTOP 2 Safety information Personnel qualifications Only personnel instructed by KÖCO who are familiar with the instructi- ons for the welding machine are allowed to work with the welding machine. Personnel to be trained and instructed or being trained are only all- ... -
Page 13: Obligations Of The Operating Company
2 Safety information ELOTOP Obligations of the operating company The operating company must ensure that the personnel work in a safety-conscious and hazard-aware manner, observing the instructi- ons and the applicable national health, occupational safety, accident prevention, fire protection and environmental regulations. They must provide regular training for the personnel as required. -
Page 14: Safety Signs And Labels
ELOTOP 2 Safety information Safety signs and labels Check the safety signs and labels on the stud welding machine regularly. Replace safety signs or labels if they are illegible. The following illustrations show the positions of the safety signs and labels on the stud welding machine using individual device variants as examples. - Page 15 2 Safety information ELOTOP ELOTOP 22 Fox ELOTOP 13 Racoon also valid for: ELOTOP 25 Tiger ELOTOP 25 Grizzly Fig. 2 Safety signs on the front of the device Follow the manual: Read the instructions before starting work and before operating the device.
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Page 16: Residual Risks
ELOTOP 2 Safety information Residual risks Danger resulting from electrical power! High currents flow during welding. Risk of electric shock. Do not touch any live parts, especially the area between the lifting sys- tem and the workpiece. Wear hand protection during welding. ... - Page 17 2 Safety information ELOTOP Warning of hot particles and ceramic splinters! Hot particles can be produced during welding and get into the eyes. If the ceramic ferrule is destroyed during welding with a ceramic ferrule, cera- mic splinters can be produced and get into the eyes. Wear eye protection.
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Page 18: Technical Information
ELOTOP 3 Technical information Technical information Functional description The ELOTOP stud welding machine is used as a welding power source and, when used in combination with a lifting system, serves to join cylin- drical pins to metallic surfaces (stud welding). It can be used for stud wel- ding with a ceramic ring, for short cycle stud welding or for gas-shielded stud welding. - Page 19 3 Technical information ELOTOP Electronic control The electronic control of the stud welding machine has the following func- tions: Ignition of an arc by a pilot current, simultaneous lifting of the stud from the workpiece to a preselected height (lift) and keeping the lift constant during the preselected welding time Constant welding current regardless of mains voltage fluctuations, ...
- Page 20 ELOTOP 3 Technical information Process Control cannot guarantee that the quality of a weld is good. It merely proves that the values specified on the device have been adhered to and that the correct amount of energy has been applied. In addition, Process Control can provide indications of certain faults (e.g.
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Page 21: Components
3 Technical information ELOTOP In order for the device to recognize which lifting system is connected and how it must control and/or calculate accordingly, the lifting system type and the operating mode must be set (see page 50). Lifting system types: "ELOTOP+"... - Page 22 ELOTOP 3 Technical information Fig. 3 Stud welding machine ELOTOP 13 Racoon (front view) Crane lug Swivel castor Handle Connection for control cable of the lifting system (4-pin) Control panel (see fig. 12, page 38) Welding socket (-) USB socket with cover 10 Connection for control cable of the lifting system (7-pin) Microfuse for fan 0.5 A (5 x 20 mm)
- Page 23 3 Technical information ELOTOP 10 9 Fig. 4 Stud welding machine ELOTOP 22 Fox (front view) Crane lug Swivel castor Handle Connection for control cable of the lifting system (4-pin) Control panel (see fig. 12, page 38) 10 Welding socket (-) Interface installation option Connection for control cable of the lifting system (7-pin)
- Page 24 ELOTOP 3 Technical information Fig. 5 Stud welding machine ELOTOP 25 Tiger (front view) Crane lug Swivel castor Handle Connection for control cable of the lifting system (4-pin) USB socket with cover 10 Connection for control cable of the lifting system (7-pin) Interface installation option Ground sockets (+), internally connected...
- Page 25 3 Technical information ELOTOP 2,5A Fig. 6 Stud welding machine ELOTOP 25 Grizzly (front view) Crane lug Welding socket (-) Handle Ground sockets (+), internally connected through USB socket with cover 10 Swivel castor Interface installation option Shielding gas supply to the workpiece (optional) Microfuse for fan 2 A (5 x 20 mm) Device connection (not visible)
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Page 26: Technical Data
ELOTOP 3 Technical information Technical data Tab. 2 Technical data of the stud welding machine ELOTOP ELOTOP ELOTOP ELOTOP Racoon Tiger Grizzly Stud diameter (Ø) for stud 3–14 mm 6–22 mm 6–25 mm welding with ceramic ferrule Stud diameter (Ø) for short- 3–10 mm –... - Page 27 3 Technical information ELOTOP Tab. 2 Technical data of the stud welding machine (cont.) ELOTOP ELOTOP ELOTOP ELOTOP Racoon Tiger Grizzly Type of cooling Temperature range -20 °C to +70 °C Storage Relative humidity up to 50 % at 40 °C up to 90 % at 20 °C Temperature range for wel- -10 °C to +40 °C...
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Page 28: Guideline Values For Welding With Ceramic Ring Or Shielding Gas
ELOTOP 3 Technical information Guideline values for welding with ceramic ring or shielding gas In fig. 7, guideline values (amperage, welding time, lift, protrusion and immersion speed) for welding with a ceramic ring or shielding gas are given, using the example of a stud with a diameter of 16 mm and alumi- nium filler metal. -
Page 29: Guideline Values For Short-Cycle Stud Welding Without Weld Pool Protection Or
3 Technical information ELOTOP Guideline values for short-cycle stud welding without weld pool protection or with shielding gas Short-cycle stud welding is used when the lowest possible penetration is to be achieved on thin sheet metals. In general, it is carried out with bolts from M 3 to M 10 (bolts with flange type PS according to DIN EN ISO 13918). -
Page 30: Material Requirements
ELOTOP 3 Technical information Material requirements In principle, drawn arc stud welding can be performed on all materials sui- table for fusion welding. However, please note that some sensitive steels may harden and thus become brittle due to the fast heating and cooling processes. -
Page 31: Scope Of Delivery, Transport And Storage
4 Scope of delivery, transport and storage ELOTOP Scope of delivery, transport and storage Scope of delivery The scope of delivery contains the following: Stud welding machine ELOTOP completely assembled in the selected configuration (standard configuration 400 V with machine connection cable and mains plug, special configurations 208 V / 230 V / 460 V without machine connection cable and mains plug) Quick Start Guide... -
Page 32: Storage
ELOTOP 4 Scope of delivery, transport and storage Observe the following information for transport: Only transport the device using the provided fixtures. Any lifting gear used for transport or loading and unloading must have a minimum lifting capacity corresponding to the weight of the welding machine. -
Page 33: Operation
5 Operation ELOTOP Operation Danger from materials catching fire due to overload or short circuit! In the event of an overload or short circuit, surrounding combustible mate- rials or objects can be ignited. Secure the supply line according to the connected cable cross-section ... -
Page 34: Requirements For Operation
ELOTOP 5 Operation Requirements for operation Make sure that the power supply is sufficiently dimensioned. Please refer to chapter 3.3. Make sure that the power connection is properly earthed. Make sure that the device is in a safe, vibration-free and dry place and ... - Page 35 5 Operation ELOTOP Fig. 8 Connection example 1 (standard): Lifting system to minus (example of ELOTOP 13 Racoon) Fig. 9 Connection example 2 (e.g. for aluminium): Lifting system to plus (example of ELOTOP 13 Racoon) 35 of 80 Original instructions...
- Page 36 ELOTOP 5 Operation 2,5A Fig. 10 Connection example 1 (standard): both lifting systems to minus (example of ELOTOP 25 Grizzly) 2,5A Fig. 11 Connection example 2 (e.g. for aluminium): both lifting systems to minus (example of ELOTOP 25 Grizzly) Original instructions 36 of 80...
- Page 37 5 Operation ELOTOP Please proceed as follows to start up the machine: Depending on the application scenario, connect the ground cable to the ground socket (standard) or to the welding socket (e.g. aluminium welds) of the stud welding machine and the workpiece. Ensure that the ground terminals are firmly attached to the workpiece.
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Page 38: Operating The Menus
ELOTOP 5 Operation Operating the menus In the menus, you can call up all relevant process data and system infor- mation and make all relevant settings for the welding parameters, process control and system settings. The menus are operated via a control panel with buttons and display field, which are explained below. - Page 39 5 Operation ELOTOP Tab. 4 Control panel/buttons 1-channel and 2-channel variant Button Function Arrow up button Parameter modification: increase the value (right) Menu navigation: Move the cursor upwards (if the menu does not contain any parameters) Arrow down button Parameter modification: reduce the value ...
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Page 40: Display Field
ELOTOP 5 Operation 5.3.2 Display field The work screen and the menus are shown in the display field. For navigation on the work screen and in the menus, please observe the following main navigation options: Press the Enter button on the work screen to access the "Current Pro- ... -
Page 41: Work Screen
5 Operation ELOTOP 5.3.2.1 Work screen Fig. 14 Work screen (example of 1-channel variant) wireless network/Internet connectivity established wired network/Internet connectivity established locking of all user inputs (key lock possible with optional key switch) USB device connected and ready for use. If the symbol is not displayed when a USB device is plugged in, the USB device is faulty or has not been detected. -
Page 42: Current Process Data" Menu
ELOTOP 5 Operation 5.3.2.2 "Current Process Data" menu You can access this menu by pressing the Enter button on the work screen. The following process data and any analysis results for the last wel- ding process carried out are displayed in this menu. Use the right arrow buttons to scroll through the list of process data. -
Page 43: Main Menu
5 Operation ELOTOP Number of measured voltage drops Short circuits: to the short-circuit voltage level (indicates droplet short circuits, for example) Analysis result: n/a / OK / Indicates whether a result is available nOK (code) or not available ( ) and whether the last weld was correct ( ) or not correct (... -
Page 44: Parameter Settings" Menu
ELOTOP 5 Operation 5.3.2.4 "Parameter Settings" menu You can access this menu via Main Menu | Parameter Settings Here you can select the following submenus from a selection list to set the parameters of the welding process, save or load data records. Set (Set Parameters) ... - Page 45 5 Operation ELOTOP Event "Save set" ("Save as") You can access this event via Main Menu | Parameter Settings | Save set You can save user data records here. A user data record contains the data set for the welding parameters and process control. You can save up to 20 user data records.
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Page 46: Process Control" Menu ("Bspk Settings")
ELOTOP 5 Operation 5.3.2.5 "Process Control" menu ("BSPK Settings") You can access this menu via Main Menu | Process Control The abbreviation BSPK in the menu title stands for stud welding process control. For information on the Process Control, see page 19. Here you can select the following submenus to view or make Process Con- trol settings: Current result (BSPK result) - Page 47 5 Operation ELOTOP "Current Reference" menu You can access this menu via Main Menu | Process Control | Current Reference The data (actual values) of the saved reference weld are displayed here: Welding current: XXX A real welding current (actual value), measured from reaching the setpo- int until short-circuit (stud contact when lowering)
- Page 48 ELOTOP 5 Operation Event "Create/Extend Reference" Make sure you set reasonable references so that the process data analysis leads to reasonable results. KÖCO recommends using several welds as a reference that show the entire spectrum of welding conditions (e.g. diffe- rent positioning of the ground terminals and distribution of the electroma- gnetic field on the workpiece) and the material properties of the work- piece (e.g.
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Page 49: System Settings" Menu
5 Operation ELOTOP 5.3.2.6 "System Settings" menu You can access this menu via Main Menu | System Settings Here you can select the following submenus from a drop-down list: Language Date & Time Counter Lifting system "Language"... - Page 50 ELOTOP 5 Operation "Lifting system" menu You can access this menu via Main Menu | System Settings | Lifting system The lifting system type and the operating mode are set here so that the machine detects which lifting system is connected and how it must cont- rol and/or calculate accordingly.
- Page 51 5 Operation ELOTOP Teach-in for gun types of the KE series (stock products only) Teach-in must be carried out in in KE mode to teach the stud welding gun to the machine, as KE series guns work in analogue mode but have an electronic lift control that adjusts the lift according to the setting via a potentiometer.
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Page 52: System Info" Menu
"System Info" menu The "System Info" menu displays system information that is relevant for troubleshooting, service and documentation purposes, for example: Product name ELOTOP+ 13 Racoon / XX XXXXX M. no.: XXXXX Machine number or product serial number Control PCB... - Page 53 5 Operation ELOTOP Battery voltage of the buffer battery. Battery voltage: XXXX V The nominal value is 3 V or 3.3 V. From 1.8 V, a message is displayed each time the machine is switched on, prompting you to replace the battery.
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Page 54: Welding
ELOTOP 5 Operation Welding Danger resulting from electrical power! High currents flow during welding. Risk of electric shock. Do not touch any live parts, especially the area between the lifting sys- tem and the workpiece. Wear hand protection during welding. ... - Page 55 5 Operation ELOTOP Welding with a KÖCO stud welding gun is described below. If you are using a different lifting system, follow the instructions for the lifting sys- tem. The procedure is basically the same. Place the prepared stud welding gun on the workpiece until the cera- mic ferrule or the support tube is in full contact with the surface.
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Page 56: Checking The Weld
ELOTOP 5 Operation Checking the weld The stud weld can be checked by means of a visual inspection and a ben- ding test (work samples). 5.5.1 Visual inspection Check the welded connection for a closed weld bead. When welding with a ceramic ferrule or shielding gas to protect the weld pool, the surface is shiny blue/grey and neither matt nor porous. - Page 57 5 Operation ELOTOP Tab. 6 Assessment of stud welds Appearance Remark Good weld One-sided melting due to blowing effect. Possible remedy: Change the connection points of the ground terminals on the workpiece Turn the gun to change the distance bet- ...
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Page 58: Bending Test
ELOTOP 5 Operation 5.5.2 Bending test The bending test makes it possible to check the strength of a weld. A posi- tive result includes the following statements: The combination of materials is suitable for welding. The welding parameters have been selected correctly. ... -
Page 59: Faults And Malfunctions
6 Faults and malfunctions ELOTOP Faults and malfunctions If errors occur that the machine detects automatically, the red error LED flashes and the error message is shown in text form in the display panel ("Error" and the cause below it). If the red error LED lights u continuously, there is an unforeseeable error (e.g. -
Page 60: Fault Messages And Troubleshooting
ELOTOP 6 Faults and malfunctions Fault messages and troubleshooting Table 7 shows possible error messages and their meaning as well as possi- ble causes and troubleshooting measures. With the help of this table below, qualified personnel can rectify many errors themselves. If there is an internal error or if the error persists despite the measures taken, please contact KÖCO Service. - Page 61 6 Faults and malfunctions ELOTOP Tab. 7 Error messages Fault mes- Meaning Potential causes Measures sage Phase failure At least one phase of Mains fuse has Check the mains fuses the mains connection tripped and switch them back on is not energised. if necessary.
- Page 62 ELOTOP 6 Faults and malfunctions Tab. 7 Error messages (cont.) Fault mes- Meaning Potential causes Measures sage Gun overcur- The current at the Short circuit in For cause 1 and 2: rent gun solenoid connec- control cable/ Remove the control cable tion is above the cable extension of or cable extension from...
- Page 63 6 Faults and malfunctions ELOTOP Tab. 7 Error messages (cont.) Fault mes- Meaning Potential causes Measures sage Loose contact Communication with Cable break Check the cable and, if of control the gun electronics is necessary, the cable cable faulty. extension. Path sensor No current loop sig- Cable break...
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Page 64: Errors Without Display And Error Rectification
ELOTOP 6 Faults and malfunctions Errors without display and error rectification Errors can also occur although they are not indicated by an error message. There are various possible causes for this: contamination/condensation overvoltage/lightning defective components thermal load ... -
Page 65: Results Of The Process Data Analysis
6 Faults and malfunctions ELOTOP Results of the process data analysis The process data analysis outputs results as a result text with a two-digit result code. The following diagram and tables show possible results of the process data analysis. Result code 1st digit (see table 10) Result code 2nd digit (see table 10) Result text (see table 9) Fig. - Page 66 ELOTOP 6 Faults and malfunctions Tab. 10 Meaning of the hexadecimal result codes Displayed result code contained error codes The possible error codes and their meaning are shown in table 11. In the example given in fig. 19, the result codes mean the following: Result code 1st digit = C ...
- Page 67 6 Faults and malfunctions ELOTOP Tab. 11 Meaning of the error codes (cont.) Error code Possible causes and measures The welding time has fallen below the target time, e.g. due to a droplet short circuit. Check whether the lifting system is working properly and repeat the welding process.
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Page 68: Results Of The Process Control (Bspk)
ELOTOP 6 Faults and malfunctions Results of the Process Control (BSPK) The results of the Process Control (BSPK) for the last weld carried out are displayed in the "Current result" menu ("BSPK result"). You can access the menu via Main Menu | Process Control | Current result The result text is displayed in the title bar of the menu. - Page 69 6 Faults and malfunctions ELOTOP The result text provides a basic assessment of the weld. Tab. 12 Meaning of the result text Result Description Potential causes Measures text There is currently no No welding has Carry out a weld. analysis data available been carried out yet.
- Page 70 ELOTOP 6 Faults and malfunctions In the CSV file, each result with result text is supplemented by a three- digit hexadecimal result code. Each digit of the result code indicates the sum of up to four error codes. Tab. 13 Meaning of the hexadecimal result codes Displayed result code contained error...
- Page 71 6 Faults and malfunctions ELOTOP Tab. 14 Results of the Process Control (BSPK) per parameter/error code Parameter Code Description Potential causes Measures The analysis The analysis (calcu- Check whether there is result is not OK lation) has failed an immersion obstruc- (requirement to (energy ≤...
- Page 72 ELOTOP 6 Faults and malfunctions Tab. 14 Results of the Process Control (BSPK) per parameter/error code (cont.) Parameter Code Description Potential causes Measures The welding There is an immer- Check whether the lif- time is greater sion obstruction. ting system can move than the limit freely and that the stud value.
- Page 73 6 Faults and malfunctions ELOTOP Tab. 14 Results of the Process Control (BSPK) per parameter/error code (cont.) Parameter Code Description Potential causes Measures The lift is greater A gun of the KE If necessary, adjust the than the limit series is connected, mode under Main menu | value.
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Page 74: Maintenance, Cleaning And Calibration
ELOTOP 7 Maintenance, cleaning and calibration Maintenance, cleaning and calibration Danger from materials catching fire due to overload or short circuit! In the event of an overload or short circuit, surrounding combustible mate- rials or objects can be ignited. Secure the supply line according to the connected cable cross-section ... -
Page 75: Maintenance And Cleaning
7 Maintenance, cleaning and calibration ELOTOP Maintenance and cleaning Before starting any maintenance work, disconnect the mains plug or, if the device connection cable is permanently connected, interrupt the power supply and secure it against unintentional restart. Check the welding machine for external visible damage and defects. ... - Page 76 ELOTOP 7 Maintenance, cleaning and calibration The accumulation of dust inside the device can lead to malfunctions of the control unit, impaired cooling and thermal overload. Open the housing at regular intervals (at least every 6 months) and blow out dust if necessary (see fig. 21). Only clean the printed circuit boards in the front area of the device's ...
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Page 77: Calibration
7 Maintenance, cleaning and calibration ELOTOP Calibration We recommend calibrating the stud welding machine at specified intervals. The manufacturer's recommendation for the calibration interval is 1 year. Further information can be found in the Technical Bulletins DVS 3009 and 0714 as well as in DIN EN ISO 17662. Have the device calibrated by the KÖCO service. -
Page 78: Disposal
ELOTOP 8 Disposal Disposal The stud welding machine contains valuable raw materials and must not be disposed of with household waste or in any other uncontrolled manner. We are registered with the German Electrical Used Equipment Register (Stiftung Elektro-Altgeräte Register ®, EAR) under the number WEEE registration no. -
Page 79: Declaration Of Conformity
9 Declaration of Conformity ELOTOP Declaration of Conformity EU Declaration of Conformity for a machine (original) The manufacturer declares sole responsibility for issuing this declaration of conformity: Köster & Co. GmbH Spreeler Weg 32 D-58256 Ennepetal Designation of the machine: Stud welding machine ELOTOP series 13 / 22 / 25... -
Page 80: Need Assistance
Need assistance? Get in touch with us! +49 2333 8306-0 info@koeco.net Köster & Co. GmbH info@koeco.net Spreeler Weg 32 +49 2333 8306-0 58256 Ennepetal www.koeco.net Germany...
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