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Summary of Contents for KÖCO ELOFIX 8
- Page 1 Original instructions KÖCO stud welding machine ELOFIX 8 These instructions are identified by part number 399-0422-000.
- 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
ELOFIX 8 Table of contents Using the instructions ....................... 5 Signal words ............................. 6 Symbols ................................ 6 1.2.1 Danger symbols ......................... 6 1.2.2 Information symbols ......................7 Safety information ........................8 Intended use ............................8 Reasonably foreseeable misuse ....................8 Personal protective equipment ....................8 General safety instructions ...................... - Page 4 ELOFIX 8 Disposal ............................37 Declaration of Conformity .....................38 Original Instructions 4 of 40...
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Page 5: Using The Instructions
ELOFIX 8 Using the instructions The KÖCO ELOFIX 8 stud welding machine has been built according to the rules of technology and complies with the technical rules and regulations applicable at the time of delivery. The instructions for the stud welding machine contain all the information needed for the safe use of the device. -
Page 6: Signal Words
ELOFIX 8 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 moder- ate injury. -
Page 7: Information Symbols
1 Using the instructions ELOFIX 8 1.2.2 Information symbols Wear protective clothing Wear head protection Wear hearing protection Wear eye protection Wear hand protection Wear foot protection 7 of 40 Original Instructions... -
Page 8: Safety Information
ELOFIX 8 2 Safety information Safety information Intended use The device is exclusively intended for drawn arc stud welding. It must not be used for other purposes. It is suitable for welding under increased elec- trical hazard (DIN EN 60974-1). Any use other than the intended use is regarded as reasonably foreseeable misuse. -
Page 9: General Safety Instructions
2 Safety information ELOFIX 8 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 ... -
Page 10: Safety Instructions For Operation
ELOFIX 8 2 Safety information Safety instructions for operation Weld spatter can ignite flammable objects several metres away, e.g. cleaning rags or packaging material soiled with oil, grease or solvents. Do not operate the device in areas where there is a risk of fire or explo- sion. -
Page 11: Personnel Qualifications
2 Safety information ELOFIX 8 Personnel qualifications Only personnel instructed by Köster & Co. GmbH who are familiar with the instructions for the welding machine are allowed to work with the welding machine. Personnel to be trained and instructed or being trained are only ... -
Page 12: Obligations Of The Operating Company
ELOFIX 8 2 Safety information Obligations of the operating company The operating company must ensure that the personnel work in a safety-conscious and hazard-aware manner, observing the instruc- tions 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 13: Safety Signs And Labels
2 Safety information ELOFIX 8 Safety signs and labels The following safety signs and labels are attached to the stud welding machine. Check them regularly. Replace safety signs and labels if they are illegible. Fig. 1 Safety signs and labels attached to the stud welding machine Rating plate: The rating plate contains the most important technical data, such as the supply voltage. -
Page 14: Residual Risks
ELOFIX 8 2 Safety information Residual risks 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 15: Technical Information
ELOFIX 8 Technical information Functional description The ELOFIX 8 stud welding machine consists of a three-phase transformer, a rectifier, a thyristor module and an electronic control unit. It is used as a welding power source and, when used in combination with a stud welding gun, serves to join cylindrical pins to metallic surfaces (stud welding). - Page 16 ELOFIX 8 3 Technical information Fig. 2 ELOFIX 8 stud welding machine Handle Ground socket (+) Control panel (see fig. 3) Mains plug connection Connection for the control line of the Shielding gas supply to the work- stud welding gun (four-pin)
- Page 17 3 Technical information ELOFIX 8 Fig. 3 Control panel Operation LED (green) Arrow down button Overtemperature LED (yellow) "GAS" key Fault LED (red) Arrow up button Segment display Gas LED (illuminated when shielding gas operation is on) 17 of 40...
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Page 18: Technical Data
ELOFIX 8 3 Technical information Technical data Tab. 2 Technical data of the welding machine Stud diameter (Ø) for stud welding with 3–8 mm ceramic ferrule Stud diameter (Ø) for short-cycle stud welding 3–6 mm (up to 8 mm with shielding gas) Stud diameter (Ø) for gas-shielded stud weld-... -
Page 19: Guidelines For Stud Welding
3 Technical information ELOFIX 8 Guidelines for stud welding The table shows the approximate setting values that have been tested for common types of studs when welding on bare metal surfaces in the flat position (PA position according to DIN EN ISO 6947). Under other condi- tions (e.g. -
Page 20: Material Requirements
ELOFIX 8 3 Technical information Material requirements In principle, drawn arc stud welding can be performed on all materials suitable 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 21: Scope Of Delivery, Transport And Storage
Scope of delivery, transport and storage Scope of delivery The scope of delivery contains the following: ELOFIX 8 stud welding machine, fully assembled with power cable in the selected version (standard version 400 V / special version 230 V /... -
Page 22: Storage
ELOFIX 8 4 Scope of delivery, transport and storage Storage Observe the following storage conditions: Store the welding machine in an upright position in a dry and clean place. Do not stack several devices. Cover the welding machine completely to keep dirt and dust away. -
Page 23: Operation
5 Operation ELOFIX 8 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 24: Commissioning
ELOFIX 8 5 Operation Commissioning Please observe the following information on selecting the connections and polarity: Generally, the stud is connected to minus and the workpiece to plus. In some cases, particularly when welding with non-ferrous metals, reversed polarity can improve the result. The power source is suitable for stud weld- ing with any polarity. -
Page 25: Selecting The Settings
5 Operation ELOFIX 8 Please proceed as follows to start up the device: Connect the ground cable to the ground socket of the welding machine and to the workpiece. The connection points on the work- piece must be made of bare metal. -
Page 26: Welding
ELOFIX 8 5 Operation Welding Warning of intense arc light! The light from the arc can cause eye injury. Do not look into the arc. Wear eye protection. Ensure that nobody enters the danger zone during operation. ... -
Page 27: Checking The Weld
5 Operation ELOFIX 8 Checking the weld The stud weld can be checked by means of a visual inspection and a bend- ing test. 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 28 ELOFIX 8 5 Operation Tab. 5 Assessment of stud welds Appearance Remark Good weld One-sided melting due to blowing effect. Possi- ble remedy: Change the connection points of the ground terminals on the base material Turn the gun to change the distance ...
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Page 29: Bending Test
5 Operation ELOFIX 8 5.5.2 Bending test The bending test makes it possible to check the strength of a weld. A pos- itive result includes the following statements: The combination of materials is suitable for welding. The welding parameters have been selected correctly. -
Page 30: Faults And Malfunctions
ELOFIX 8 6 Faults and malfunctions Faults and malfunctions Fault messages and troubleshooting 6.1.1 Faults displayed on the front panel Fig. 9 Indication of faults on the control panel Operation LED (green) Fault LED (red) Overtemperature LED (yellow) Segment display... - Page 31 6 Faults and malfunctions ELOFIX 8 The following faults are displayed directly on the front panel and/or on the welding machine's segment display: Tab. 6 Faults on the control panel Segment LED display Meaning Measure display The Fault LED (red) is Gun overcurrent/short illuminated.
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Page 32: Faults Not Displayed
ELOFIX 8 6 Faults and malfunctions 6.1.2 Faults not displayed With the help of the troubleshooting table below, qualified personnel can rectify many faults themselves. If the fault cannot be rectified, contact the KÖCO service or the field service. Please have the device type and serial number to hand, as well as a detailed description of the fault. - Page 33 6 Faults and malfunctions ELOFIX 8 Tab. 7 Faults not displayed Notes and explana- Fault Cause Remedy tions Clean the workpiece surface Bare metal surfaces pro- in the welding area and at vide optimum welding the clamping point of the results.
- Page 34 ELOFIX 8 6 Faults and malfunctions Tab. 7 Faults not displayed Notes and explana- Fault Cause Remedy tions Make sure that the stud tip is This error occurs, for The gun pis- Pilot arc fails in direct contact with the...
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Page 35: Maintenance, Cleaning And Calibration
7 Maintenance, cleaning and calibration ELOFIX 8 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. -
Page 36: Calibration
ELOFIX 8 7 Maintenance, cleaning and calibration Calibration We recommend calibrating the stud welding machine at specified intervals. The manufacturer's recommendation for the calibration interval is 1 year. For further information, please refer to Technical Bul- letins DVS 3009 and DVS 0714. - Page 37 8 Disposal ELOFIX 8 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.
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Page 38: Declaration Of Conformity
ELOFIX 8 9 Declaration of Conformity 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 Stud welding machine... -
Page 40: 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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