STAUFF SWG-WI06 User manual

©Walter Stauffenberg GmbH & Co. KG

Local Solutions For Individual Customers Worldwide

SWG-WI06

Operating Manual

©Walter Stauffenberg GmbH & Co. KG

2

After-sales service for Germany:

Walter Stauffenberg GmbH & Co. KG

Im Ehrenfeld 4

58791 Werdohl

GERMANY

Phone +49 (0) 23 92 / 916 - 0

Fax +49 (0) 23 92 / 25 05

E-Mail [email protected]

Web www.stauff.com

SWG-WI06 Operating Manual Issue 2016-06

Translation of the Original Operating Manual

Please keep the manual in a safe place for future reference.

Transmission and duplication of this document, dissemination and notication

of the contents are not permitted unless expressly approved.

All rights, errors and technical amendments reserved.

3

©Walter Stauffenberg GmbH & Co. KG

Dear Customer,

Many thanks for buying a stud welding machine from STAUFF.

We at STAUFF wish you success at all times when working with this

stud welding machine.

The high level of quality of our products is guaranteed by ongoing further

development in the design, equipment and accessories. This may result in

differences between the present operating manual and your product.

No claims can therefore be derived from the data, illustrations and descriptions.

We have compiled the data and information in this reference work with the greatest

care, and have made every effort to ensure that the information contained in this

manual was correct and up-to-date at the time of delivery. We can nevertheless

give no guarantee for an absolutely error-free document.

Should you discover any errors or unclear points when reading this

operating manual, please do not hesitate to contact us.

We would also be grateful for any feedback should you have any suggestions

or complaints to make about our product.

Walter Stauffenberg GmbH & Co. KG

Im Ehrenfeld 4

58791 Werdohl

GERMANY

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Table of Contents

©Walter Stauffenberg GmbH & Co. KG

Table of Contents

1 Important Safety Precautions �� 6

2 Symbols and Terms Used �� 9

3 Scope of Supply �� 12

4 Accessories �� 12

5 Technical Data �� 13

6 Intended Use �� 14

6.1 Usage with STAUFF Clamps ................................................................................ 14

7 Warranty �� 15

7.1 Disclaimer ............................................................................................................. 15

8 Components of the Stud Welding Unit �� 16

8.1 Main Assemblies ................................................................................................... 16

8.2 Operation Panel and Display ................................................................................ 18

8.3 Mains Switch ........................................................................................................ 18

9 Welding Process �� 19

Drawn-Arc Stud Welding ...................................................................................... 19

10 Preparing Workplace and Welding Process �� 23

10.1 Preparing Surfaces ............................................................................................... 24

10.2 Checking the Stud Welding Gun .......................................................................... 25

11 Connection �� 26

11.1 Connecting the Welding Gun to the Stud Welding Unit ........................................ 27

11.2 Connecting the Ground Cable .............................................................................. 28

11.3 Connecting the Stud Welding Unit to the Mains Supply ....................................... 29

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Table of Contents

©Walter Stauffenberg GmbH & Co. KG

12 Welding �� 30

12.1 Switching on the Stud Welding Unit ..................................................................... 30

12.2 Determining the Welding Time and the Welding Current ...................................... 31

12.3 Setting the Welding Parameters ........................................................................... 34

Adjusting the Welding Time ................................................................................................ 34

Adjusting the Welding Current ........................................................................................... 34

12.4 Performing the Welding Process .......................................................................... 35

13 Checking the Quality of the Weld �� 39

13.1 Carrying out Visual Inspection .............................................................................. 39

13.2 Carrying out Bending Test .................................................................................... 40

13.3 Optimisation of Welding Parameters .................................................................... 42

13.4 Blowing Effect and Remedies ............................................................................... 43

14 Troubleshooting �� 44

15 Shutting Down �� 46

16 Maintenance and Care �� 47

16.1 Cleaning ............................................................................................................... 47

16.2 Inspection and Tests ............................................................................................. 48

17 Storage �� 49

18 Disposal �� 49

EC Declaration of Conformity �� 50

Service & Support �� 51

Index �� 52

6

1 Important Safety Precautions

©Walter Stauffenberg GmbH & Co. KG

1 Important Safety Precautions

The target group for this manual are qualied personnel who in view of their

technical training, know-how and experience and knowledge of applicable

regulations are able to assess the work assigned to them and recognise potential

hazards.

Danger from incorrect use

Use the stud welding machine only for the purpose described in this

manual.

Otherwise you may endanger yourself or damage the stud welding machine.

You endanger yourself and others if you operate the stud welding machine

incorrectly or fail to observe the safety precautions and warnings. This can

lead to serious injury or extensive material damage.

Danger for unauthorised operating personnel

Work with the stud welding machine only when

– You are appropriately trained, instructed and authorised to do so, and

– You have read and completely understood this operating manual.

Never work with the stud welding machine when you are under the

inuence of

– Alcohol,

– Drugs or

– Medication.

Danger from unauthorised modications

Never modify the stud welding machine or parts thereof without obtaining

a clearance certicate from the manufacturer.

You will otherwise endanger yourself. This can lead to serious injury or

extensive material damage.

7

1 Important Safety Precautions

©Walter Stauffenberg GmbH & Co. KG

Danger for wearers of heart pacemakers

Never operate the stud welding machine if you have a heart

pacemaker.

In this case, never remain in the vicinity of the stud welding machine

during welding.

Never operate the stud welding machine if persons with heart

pacemakers are in the vicinity.

Strong electromagnetic elds are produced in the vicinity of the stud

welding machine during welding. These elds may impair the function

of the heart pacemakers.

Danger from fumes and airborne particulates

Switch on the welding fume extractor at the place of work.

Ensure that the room is well ventilated.

Never weld in rooms with a ceiling height of less than 3 m.

Observe furthermore your working instructions and the accident

prevention regulations.

This will help to avoid health damage due to fumes and airborne parti-

culates.

Danger from glowing metal spatter (re hazard)

Glowing hot weld spatter and liquid splashes, ashes of light and a

loud bang > 90 dB (A) must be anticipated during stud welding.

Inform colleagues working in the immediate vicinity accordingly

before starting work.

Ensure that an approved re extinguisher is available at the

workplace.

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1 Important Safety Precautions

Do not weld when wearing working clothes soiled with ammable

substances such as oil, grease, petroleum, etc.

Wear your proper protective clothing, such as:

– Protective gloves in accordance with the relevant standard,

– Non-ammable clothing,

– A protective apron over your clothing,

– Full-ear hearing protection in accordance with the relevant

standard,

– A safety helmet when welding above your head,

– Safety shoes,

– Safety goggles with sight glass of protection level 2 in

compliance with the applicable standards and do not look

directly into the light arc.

Remove all ammable materials and liquids from the vicinity of the

work area before starting welding.

Weld at a safe distance from ammable materials or liquids.

Select a safety distance large enough to ensure that no danger can

arise from weld spatter.

Protection of the stud welding unit

Protect the stud welding machine against the ingress of foreign

matter and liquids caused by cutting or grinding work in the vicinity

of your work area.

This will help to prolong the service life of your stud welding machine.

9

2 Symbols and Terms Used

The symbols used in this operating manual have the following meanings:

Danger

Warns you of hazards that can lead to injury of persons or to

considerable material damage.

Caution

Problems with the operating procedures can occur if this information is

not observed.

No access for people with active implanted cardiac devices

Danger

Warns you of electrical hazards

Danger

Warns you of electromagnetic elds that can be generated during welding

These symbols prompt you to wear personal protective clothing when

working with the stud welding unit.

This symbol prompts you to wear ear protection.A loud bang > 90 dB (A)

can occur during the welding process.

10

2 Symbols and Terms Used

Tip

Cross-reference to useful information on the use of the stud welding

machine

Cross-references in this operating manual are marked with this

symbol or are printed in italics

Fire hazard

Have a suitable re extinguisher for the working area ready before starting

work.

Work instruction

– List

STAUFF SWG-WI06 User manual

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