SAW D Manual

7/28/2019 SAW D Manual

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HONGBAITECHNOLOGY

INDUSTRIAL CO., LTD

OPERATING MANUAL FOR SAW-D / / SERIESDIGITAL CAPACITOR DISCHARGE

STUDWELDING EQUIPMENT

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Content Page

1 General Information 1

2 Working Principle and Structure 1

2.1 Principle 1

2.2 Structure 2

2.3 External Features, Symbols, and Functions 4

3 SAW-D Series Technical Data 5

4 Setting Up and Wielding 5

4.1 Cautions 5

4.2 Setting Up 6

4.3 Wielding 6

5 Quality Control 7

5.1 Quality Standard 7

5.2 Personnel Requirement 7

5.3 Test Method 7

5.4 Test in Practice 8

6 Maintenance 8

6.1 Stud Wielding 8

6.2 Replacing Components 9

7 Failure Analysis 9

7.1 Failure Code 9

7.2 Failure Instructions 10

8 Services 11

8.1 Before-Sale Service 11

8.2 After-Sale Service 11

9 SAW-D Series Circuit Schematic 12

10

SAW-D Series Standard Deployment 13


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1. General InformationShenzhen HongBai Technology Industrial co., LTD is a company specialized in

researching and manufacturing of stud wielding. The company owns a team of

senior professionals of wielding technology. With over 10 years in studweldingindustry, we have designed and manufactured advanced and finest studwelding

equipments and their automation equipment series, granted by the nation the

torch program certificate-approval number: [2003I98].The company was assessed

and registered against the following quality management standard: ISO9001:

2000 in the year 2004.

SAW-D / / series is capacitor discharge stud wielding equipment, it

applies advanced micro processing technology, which can be used to control wielding time sequence, the amount of electricity released by the capacitor and

monitor the operating condition. SAW-D / / series can weld studs directly

on mild steel, stainless steel, aluminum and copper; The largest welding thickness

can be up to 10mm. With the features of easy and convenient handling, steady

welding and barely deforming, they can be widely applied in automobile, aviation,

shipbuilding, metal processing, building decoration, construction, elevator

manufacturing, kitchen equipment, boiler making, sheet metal, height voltage

swith plank, distribution box, heat insulation industry.

2. Working Principle and Structure2.1 Principle Monophase 220V mains supply can be transformed into two voltages, one

19V supplies power for the whole machine after rectifying; The other rectified

200V charge the capacitor, the voltage between the two ends of the capacitor can

be controlled and regulated by controlled silicon, range from 25V to 200V.

Controllable silicon phase synchronous controller can be finished by MCU. It can

synchronize the shutdown of controlled silicon with itself; it can also identify the

null point of the AC Mains Supply Voltage accurately. Internal phase shift control

circuit controls and regulates the phase shift, drive the controllable silicon after

being amplified and reshaped, and controls the height of voltage between the two

ends of the storage capacitor through regulating the conduction angle.The program of MCU controls working sequence, phase shift control quantity,


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data gathering, monitoring, transferring and protecting functions, etc.

While welding, discharge SCR triggers by conduction, the charges on the

storage capacitor impose between studs and the workpiece through discharge

circuit, produce electric arcs and discharge at the tip with the power stored in thecapacitor, and generate great quantity of heat within a very short time

(0.001~0.003s), forming a 0.5mm molten pool on the surface of the melting metal,

which can bond studs and the workpiece together firmly.

2.2 StructureSAW-D / / series consist four parts. One is CPU board, mainly in charge

of processing the collected signals, displaying, man-machine interaction and

sending orders to the main control board. The second one is main control board,mainly in charge of amplifying, processing voltages and current analog signals, and

controlling the conduction and shutdown of SCR. The third one is the main circuit

which is an execution unit controlling the charging and discharging of storage

capacitor. The last part is chassis and operation panel, used for man-machine

communication and protection. The operation panel is as shown in the picture.


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SHENZHEN HONGBAITECHNOLOGY INDUSTRIAL CO., LTD

1 4 5 6 7

8 3 4 5 6 7 8 2 3

8 8 8 70 100 115 140 175 190

9

10 11 12

13

15

220mm

16 17

240mm

Classis size: 440 240 220mm


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2.3 External Features, Symbols, and Functions

No. Symbol Name Function

1 8 8 8

Digital TubeDisplay reserved capacitance charge voltage valueand working status information

2 IncreasingFunction Key

Increase the charging voltage of the storage capacitor

3Decreasing

Function Key Decrease the charging voltage of the storage capacitor

4Green

LuminotronReadiness Indicator. Lit up when the capacitance value reaches the set point

5Green

Luminotron Contact indicator. Lit up when Stud contacts the workpiece. (Proper ground is required!)

6Green

Luminotron

Relay released indicator. Lit up when the welding

pistol is triggered, welding starts

7Red

Luminotron Malfunction indicator

8Stud

diameterDiameter of the studs to be welded

9 8 8 8 Welding

parameter listThe reference setting value of stud diameter andcharging voltage

10 Control lineoutlet Control line of the pistol switch. When the machine isset, it is ready to switch on and weld

11Pistol

TerminalMark the terminal of pistol wire. Used to connect thepistol wire

12Ground

TerminalMark the terminal of ground terminal. Used toconnect the ground with the workpiece

13 Power switch Used to turn on and off the welding power

14 Power fuseholder For overcurrent protection

15 Power outlet Welding power cable connection. Used for connectingsingle-phase 220V AC power

16 Fan guard Security

17 Nameplate Production description


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3. SAW-D Series Technical Data 1. Weldable Materials: Low carbon steel, Stainless steel, Aluminum, Copper, etc.

2. Weldable Thickness of the Work Piece: 0.2~10mm

3. Weldable Stud Diameter: D / Series 2~8mm; D Series 2~10mm

4. Welding Time: 0.001~0.003s

5. Standard Pistol: SAW--DH

6. Input: 220V AC 10% Frequency: 50~60Hz 1% Single-phase

Rated Capacity: D Series 300W; D / Series 350W

7. The Range of Capacitors Charging Voltage: 25V~200V

8. Capacity of Storage Capacitor:

D Series 66000uF; D Series 72000uF; D Series 108000uF

9. Welding Productivity: 15/min10. With monitoring and protection functions of input and output voltages.

11. Charge over-current protection

12. Weight: D Series 15kg; D Series 18kg; D Series 20kg

13. Required Working Condition: The ambient air temperature: -10 ~ +40 The relative temperature of the ambient air: 5 (40 ); 90 (20 )

4. Setting Up and Wielding4.1 Cautions

The welder must be installed on a horizontal surface. The four rubber feet on

the welder base are nonskid and shock-proof. Although the welder is able to withstand regular impact, but it still needs to be

taken care of the shock and dust. Please pay attention to the safety and security of the seat of the welder.

Please ensure that there is enough space around the welder for heatdissipation.

The welder should be placed near the welding area. Please ensure the right connection to the electricity. Too long the cable will lead to a voltage drop, so please choose a proper length. Please ensure the air circulation of the factory building. The fuse specifications for SAW-D : General supply insurance an F (12A). The fuse specifications for SAW-D s internal circuit boards: Charging

insurance F1 (6.3A); Control insurance F2 (2A); Fan insurance F3 (0.25A).


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Warning: The insurance can only be replaced with the ones which has

corresponding electrical parameters. The insurance that exceed the

specifications would lead to fatal danger caused by fire or electrical failures.

Power must be cut off before replacing the insurance.

4.2 Setting Up Connecting one end of the ground wire to the ground interface, the other end

to the proper position on the workpiece. Connecting the pistol connection to the pistol interface on the welding

machine, and rotate it clockwise until it is locked. Plugging the control cable into the control cable interface on the welder, and

tighten the lock screw.

Plug one end of the power cord into the power outlet on the welder, and theother into the AC 220V power.

Note: All connections must be tightened.4.3 Wielding

Switch on the welder, the 4 LED indicators on the front panel briefly shinning

on boot-up; the welder should be restart when E-2 error message displayed on

the LED display. If it still shows error, then troubleshooting has to be done. Settings of the Welder: The parameters of the stud welding machines vary

depending on the pistol types and welding materials, they should be set

according to the actual situations. While under normal situations, they could

be set according to the parameters on the front panel.

Type parameters:

3 4 5 6 7 88 8 8 70V 100V 115V 140V 175V 190V

Type parameters:2 3 4 5 6 7 8

8 8 8 40V 65V 95V 110V 130V 160V 180V Type parameters:

2 3 4 5 6 7 8 108 8 8 40V 60V 90V 105V 125V 155V 170V 190 V Note: The parameters above are for aluminum studs

welding, only for reference; the parameters can be reduced while welding iron or stainless iron studs.


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The actual charging voltage varies depending on different stud diameters. The contact indicator would light up when placing the welding pistol equipped

with studs on the surface of the workpiece. Pulling the switch of the pistol, and then the release relay indicator is lit, the

welding process begins. Note: To ensure a normal welding process, the switch of the pistol needs to be

pulled quickly. In the whole welding process, the pistol needs to be

perpendicular to the workpiece surface, and it should be moved away from the

surface after the welding. Sometimes there might be operations mistakes such

as slip when welding, these can be detected by the welder and the fault

indicator lit up. In this case the welder needs to be restarted.

Shutting down the welder: Turn off the power switch behind the welder,disconnect the mains, welding, control and ground cables.

5. Quality Control5.1 Quality Standard

Peoples Republic of China Machinery Industry Standard JB/T8323-1996

Stud Welder. The standards of the Shenzhen Hongbai Technology Industrial Co., Ltd Auto

body and coated steel planting studs series equipment

5.2 Personnel Requirement Qualified and Responsible. The operators can operate and manage the welders only after they have the

appropriate training and get the corresponding qualifications. The connection and maintenance works can only be done by personnel who

have received electrical training.

5.3 Test Method

To guarantee that the correct use of the stud welder system and the rightchoice of welding material s, the strength of the welding surface shouldalways be bigger than that of the studs. Additionally, there should also be the

following tests in the general production practice: The standard test: Typically, the standard work test must be taken repeatedly

before the actual welding practice, and the test should be under the

supervision of the user. The number of the welding tests could be decided by

the engineer in charge based on the actual situation. The standard test may be

affected by the stud diameter, the material of the workpiece and the device


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type. The test includes visual inspection (all samples), tensile testing (at least 3)

and the bending test (at least 3). Simple test: Used to test welding settings and features. This test should be

taken after some time of continuous welding. It includes visual inspection (all

samples) and the bending test (all samples).

5.4 Test in Practice Test samples: the studs to be used for the test are welded on a base metal, size

less than 700*200mm. The welding position and the distance from the edge

should all be the same. Visual inspection: used for a cursory examination for the main problem, for

estimating the identity of the weldment. In case of uncertainty, tensile testing

and torsion testing are highly recommended. Tensile testing: tensile testing is aimed at testing the bond strength between

the stud and base metal. The minimum testing stud number is three. Add an

increasing axial tension on the stud until the fracture occurs. If the user prefers

to process a stud pull test in a certain percentage, special stress meter devices

are required. If the fracture occurs outside the weld zone, then it is a successful

welding. If it happens in the zone, then an extra test about the fracture is

needed. The unwelded area should not exceed 20% of the total welding area.

When there are questions, please contact the company or the regional office. If

the number of the failed welding studs exceed the specific standard value, then

the reason of the failure must be found, the parameters must be corrected, and

a re-test is needed. Bending test: Used to cursory examine the chosen parameters. Using a specific

tube to bend the stud (at least 3 studs in the test) 30 degrees, if there is no

crack or fracture, the welding is successful. If not, and the number exceeds the

standard value above, then the reason and a re-test is necessary.6. Maintenance

6.1 Stud WieldingBased on the structure of the stud welder, its outside does not need to be

cleaned very often; however, the inside needs to be cleaned regularly according to

the exterior environment.


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6.2 Replacing ComponentsDamaged components must be replaced by service or trained andauthorized personnel. And the quality of the welder can only beguaranteed by using the original accessories.

7. Failure Analysis7.1 Failure Code When there is a fault, the fault code appears in the digital display.

Fault code Description Reason

C-1 Supply voltage fault Too large the voltage deviation

C-2 Exceed discharging durationDischarging circuit hardware

failure

C-3 Exceed charging durationCharging circuit hardware

failure

C-4Transformer

over-temperatureExceed the welding period

C-9

Too large the difference

between the actual value andset value

Charging or discharging circuitfailure

Safety Warning

The power supply must be cut off before opening the chassis. Only trained and qualified technicians are allowed to open the chassis and

replace the electrical components. Contact the company or regionaloffice when necessary.

Safety Warning

Please make sure that the capacitors have discharged completely before the replacement of the components.


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7.2 Failure InstructionsFault Reason Solution

No welding,

no dis-charging

Doesnt boot up Boot up, the ready indicator is lit

Welding, control cable is notconnected or damage, theground is not connected withthe workpiece

Check the connection and damage,replace the components whennecessary.

There is no metal mediadetected at the contact pointof the pistol and ground withthe workpiece

Amending the workpiece or stud

The switchis on, but itdoes not work

Power supply failure Check the power supply insurance

Welder insurance damage Replace the insurance

Error message Restart

The welderis ready, but there isno welding

arc

There is no tip on the top of the stud

Use the stud with tip or decreasethe center area

Problem with the controlsegment

Contact the service personnel of thecompany

Stubs loosely contact withthe current contact nozzle

Press or hoop tight the currentcontact nozzle

Thread burned

The current contact nozzle istoo old

Replace the current contact nozzle

The welding voltage is set toolarge

Adjust the welding voltage

The weldingeffect isinstable

Cable connector is nottightened

Tighten the cable connector, clampthe ground cable

Stud not clampedClamp the stud, replace the currentcontact nozzle when necessary

The stud does not get intothe contact nozzle completely

Help the stud get into the currentcontact nozzle completely

Magnetic blow, the arcdeviates to a direction

Change the position of the earthclamp, add metal pieces on the edgeof the workpiece and turn the pistol


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8. Services8.1 Before-Sale ServiceProvide technical advices to the customers about machine selection and

function deployment proactively; Specialize design and manufacturing in order

to meet the special need of different users.

8.2 After-Sale ServiceOur promises: One year warranty and lifetime maintenance.

The professional technician will come up with a solution within one day after the

customers call for repairment. For the breakdown that cannot be repaired by the

customer, please send the machine back to the company for repairing. For the

machine that is still under warranty, we will repair it free of charge, and pay

one-way freight; for the machine outside the warranty period, we only charge thecost of materials, the round-trip transportation costs should be borne by the

customer.


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9. SAW-D Series Circuit Schematic


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10. SAW-D / / series standard deployment

NO Name Specifications/Model Number Remarks

1 Host power supply SAW-D 1 Configure basedon model

2 Pistol SAW-DH 1

3 Pistol ground wire SAW-D 2

4 Current contactnozzle M3, 4, 5, 6, 8 5

5 Current contactnozzle lock wrench SAW-D 1

6 Cable connector lock wrench SAW-D 1

7 Instructions SAW-D 1

8 Warranty card SAW-D 1

9 Certificate SAW-D 1

Note: Type D has an extra M10Current contact nozzle


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SHENZHEN HONGBAI TECHNOLOGY INDUSTRIAL CO., LTD

Address: 5/F, Huolibao BLDG, 5#Rd., Northern Section, ShenzhenHigh-tech Industrial Park, Shenzhen, Guangdong, China Tel: 0755-26013288/26013326/26983368

Fax: 0755-26013188

http: //www.sawchina.cn

E-mail: [email protected]

SAW D Manual

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