CHECKLIST

Safety at work during stud welding jobs
Increased electrical hazard (Narrow and damp rooms, predicaments)

Use only devices with S or K characters. Wear dry protective clothing.

Protective clothing

Leather apron, glove, protective goggles (Protection level 2 DIN EN 169), insulating footwear and in case of overhead work in predicament head an neck protection
Fire hazard

Check environment for fire hazard by welding splashes

Respiratory protection

Sufficient ventilation at the welding site! Be careful with chrome-nickel steels and coated surfaces!        

Magnetic fields

High magnetic fields can affect pacemakers!
Carriers of implants and / or cardiac pacemakers, pregnant women and adolescents under 18 years are not allowed to perform any welding work!
Welding current lines should not be overshadowed during welding work / Please also note the information on the distances between current cables in DIN EN 60974-10!
Data storage, mobile devices and chip cards can be destroyed by the high welding currents!

Thickness of workpiece

Workpiece must have at least thickness of the stud diameter!

            
Operating personnel
Requirements

Experience with the handling of stud welders!

Audit

If the quality requirements of DIN EN ISO 14555 apply, the welding personnel must have an operator test in accordance with DIN EN ISO 14732!

   
Welding gun
Accessories

Select and properly mount suitable chucks, ceramic ferrule holders, foot plates and pillars.

Check the movement mechanism

Move piston against spring pressure, no extraordinary friction! Check Immersion damping (if available)       

Chuck

Move piston against spring pressure, no extraordinary friction! Check Immersion damping (if available) Check for stains and tension,
Push the stud into the stud holder as far as it will go!

Alignment stud and ceramic ferrule       

Foot plate with ceramic ferrule holder centric
aligned to the stud!     

Lift and overlap

Select lift and stud overlap according to stud diameter and material and check with way measurement system (display of ACTUAL values in graphic display / main menu of power unit)!

   
Welding power source
Main power connection         

Mains power must be sufficient be dimensioned! Different observe mains voltage abroad!        

Installation site

Please notice that devices not taken into
closed metallic containers and plants!

Selection of welding parameters

Current: approximately stud Ø x 70 - 80 (90)
Time: approximately stud Ø x 30 - 40

Functional running

Check function sequence
("Start", "Magnet", "Overtemperature" "Ready" indicators and all other indications of device and / or process specific errors and warnings in the main menu)

   
Cables and plugs
Cable length

Long welding cables cause losses!
Do not wind up welding current cables to form a coil!

Electrical connections and plugs

Plugs, connectors and ground terminals
check for tightness!

Cables

Welding cable and control cables
Check damages!

   
Workpiece

Ground clamps (mass)

Workpiece be metallically cleaned at the mass positions! Watch out for stains and tightness of clamps!

Surface

Welding position must be metallic cleaned and free of impurities such as tinder, rust, oil and coatings
(zinc)!

   
Trial weldings and testing

Before starting work

Make welding samples at the same materiel for testing welding performance (Mechanic solidity, closed collet)

Verify

Perform visual and bending test and
adjust parameters if necessary!

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