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Operating Manual KÖCO Compact Stud Welding Equipment 2305i KÖCO Stud Welding Guns CLASSIC SK 14 from no. 10000 SK 14-ISO from no. 17200 SK 14 short SK 15 K 22 K 22-D K 24 K 26 This operating manual has the part-no. 399-0522-000. It is a translation of the original document.
58256 Ennepetal Germany, North Rhine Westphalia Product Type: stud welder Product Model: 2305i Serial Number: 79050241 - The object of the declaration described above is in conformity with the essential requirements and other relevant requirements of the: Supply of Machinery (Safety) Regulations 2008 (S.I. 2008/1597) Electromagnetic Compatibility Regulations 2016 (S.I.
Die alleinige Verantwortung für die Ausstellung dieser Konformitätserklärung trägt der Hersteller: Köster & Co. GmbH Spreeler Weg 32 D-58256 Ennepetal Bezeichnung der Maschine: Bolzenschweißgerät Serien- / Typenbezeichnung: 2305i Seriennummer: 79050241 - Der oben beschriebene Gegenstand der Erklärung erfüllt die einschlägigen Harmonisierungsrechtsvorschriften der Union: 2006/42/EG Maschinenrichtlinie 2014/30/EU Elektromagnetische Verträglichkeit (EMV-Richtlinie)
Table of Contents Operating Manual KÖCO Compact Stud Welding Equipment 2305i KÖCO Stud Welding Guns CLASSIC SK 14 from no. 10000 SK 14-ISO from no. 17200 SK 14 short SK 15 K 22 K 22-D K 24 K 26 UKCA-Declaration of Conformity Original-EG-Konformitätserklärung...
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Remedies for Malfunctions Other Malfunctions Pictures of the Power Source 2305i Spare Parts for Welding Power Source 2305i Pictures of Stud Welding Guns CLASSIC Spare Parts for Stud Welding Guns CLASSIC Spare parts list gun series SK 14 and SK 15...
Safety Instructions The KÖCO stud welding equipment 2305i and the KÖCO stud welding gun CLASSIC is designed for use in drawn- arc stud welding only. It must not be used for any other purpose, with the exception of manual electrode welding, and then only if the appliance is equipped for this purpose.
▪ During the welding process, persons wearing heart pace-makers must be kept at a safe distance from the ap- pliance and the welding cables, because the strong magnetic fields could endanger their lives. ▪ In addition to the above, all normal accident prevention regulations must be observed. 1.2.2 Operational Safety of the Equipment ▪...
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▪ Do not carry out welding on hollow objects which contain, or have contained, inflammable liquids or gases, or which are under pressure, or inside which a dangerous level of pressure can be generated by welding heat! ▪ The heat generated by welding may lead to the release of gases or vapours which are dangerous to health or even explosive.
Drawn Arc Stud Welding Drawn-arc stud welding is used for the welding of metallic parts, generally of cylindrical shape, onto metallic work- pieces. For this purpose, a DC power source and a mobile device, the welding gun, are required. Depending on the type of welding-pool protection and welding time range used, the appropriate process may be stud welding with a ceramic ferrule, stud welding with with shielding gas, or short-cycle stud welding, either with or without shielding gas.
Technical Data on Power Source 2305i Technical data 2305i Stud welding with ceramic ferrule weldable stud range Ø (mm) 2 - 25 Short-cycle stud welding weldable stud range Ø (mm) 2 - 12 3 – 12 (16) Stud welding with shielding gas weldable stud range Ø (mm)
The Power Source The power source consists of a primary chopped inverter with constant current control, a choke connected in se- ries, and an electronic control. The machine is laid out for a mains voltage of 400 V (3-phase). Operation with other voltages is also possible by interposing a transformer.
damping. (For settings refer to Section 3.2.12). Technical Data on Stud Welding Guns CLASSIC SK 14 SK 14- Technical Data (short) SK 15 K 22 K 22-D K 24 K 26 Stud welding with ceramic ferrule 4 – 19 4 - 12 4 - 12 4 - 12 4 - 14...
Setting Guidelines for welding with ceramic ferrule or shielding gas The settings given in figure 2 have been tested for welds on clean metallic surfaces and standard type studs in downhand position. The decisive parameter is the actual diameter at the welding end of the stud, not the nominal diameter.
Setting guidelines for short cycle stud welding without weld pool pro- tection or with shielding gas Short cycle stud welding is used where it is desirable to keep the penetration on thin workpieces as shallow as possible, normally with studs ranging from M 3 to M 12 (PS type flanged studs according to EN ISO 13918). If the outward appearance of welding collars is not important, protection of the welding pool can be omitted.
Working with the stud welding equipment Requirements before starting-up 1. Ensure adequate power supply, according to instructions under section 2.2. 2. The power connection must be earthed according to regulations. 3. The housing of the welding power source must not have any electrical contact with the workpiece. Make sure that the insulating wheels (casters) are in perfect condition! 4.
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8. Only when welding with a ceramic ferrule: Place a suitable ceramic ferrule into its grip. Check the centering of the footpiece by manually pulling back the piston of the gun and then slowly releasing it again. The stud should then move forward without pushing the ceramic ferrule out of its guide. If the ceramic ferrule is pushed out, loosen the footpiece and improve its centering.
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12. Selection of damping (K 22-D, K 24 and K 26 guns only): The damping adjustment screw is situated be- tween the two legs at the front of the gun. In general, damping is only used with studs from 14 mm in diameter, to prevent splashing of the welding pool while the stud plunges.
Starting-up of the Power Source 1. Insert the mains plug into the socket and lock it into position using the lock ring (if available). 2. Connect the ground cable to the ground sockets of the welding power source and the workpiece. The connec- tion points on the workpiece must be bright metal.
Welding current and welding time are set on the front plate of the power source. Press the up and down arrow keys on the left to increase or reduce the current. Use the up and down arrow keys on the right to lengthen or shorten the time. Fig. 9: Operating terminal of the 2305i power source 3.4.2 Retrieval of parameter settings Pressing the “MENU”...
Fig. 11: Memory menu 3.4.4 Setting of shielding gas preflow time, amperage and time of pilot current Pressing the MENU key three times will take you to the shielding gas and pilot current menu. When you press the left-hand (up or down) arrow keys, the arrow on the left of the display will move between the three parameters. By pressing the right-hand (up or down) arrow keys you can change the parameter in front of which the arrow is placed upwards or downwards, or proceed to the corresponding submenu by pressing the enter (...
3.4.4.2 Setting of the amperage and time of pilot current The pilot current can be altered within a range from 5 to 25 A. It serves to ionize the arc path prior to the actual welding process. In the case of a soiled surface, a longer pilot current phase with a higher current can improve the welding results due to its cleaning effect.
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3.4.5.1 Results and reference In this menu, the actual values of the most recent weld and the reference values are displayed. If the permissible deviations from the reference value (see menu Limit values / tolerances) have been exceeded, the value affected will be shown inverted and flashing.
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values reached are displayed for each weld. Here, attention must be paid to the memory capacity of the data car- rier. Issue 02/2023 ver. 1.4 Page 23 of 72 Köster & Co. GmbH • D-58256 Ennepetal • Spreeler Weg 32 • Tel. +49 2333 8306-0 • Fax +49 2333 8306-38 •...
3.4.5.4 Setting of reference After you have found the optimal settings by means of test welds and confirmed them by appropriate tests, you can save these as a reference by pressing the enter key ( ). If process control is active, all welds will now be com- pared with this reference (not with the set point values!).
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The languages are displayed in blocks of three, with the designation of each shown in its own national language. By pressing the (right-hand or left-hand) up or down arrow keys, the remainder of languages available will be dis- played and can be selected. The language highlighted by flashing is active (for example English in Fig. 19, shown by inverse display).
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3.4.6.4 USB stick Only USB flash drives may be connected as data carriers, not consumers with higher power consumption such as external hard disk drives! You can record the welds carried out on a suitable USB data carrier. If you select this menu item although no data carrier is connected, you will receive the following signal: Fig.
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3.4.6.5 Data evaluation For evaluation of the recorded data, we supply the programme “Weldlogreader” (currently available in German only). When you open the file “welding.log” in this programme, the following picture will appear (example): Fig. 25: Display of a weld in Weldlogreader (all values within tolerance) You can use the arrow keys to select a particular weld.
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Letter Meaning Current too low Current too high Time too short Time too long Lift too short (not relevant for 2305i) Lift too long (not relevant for 2305i) Voltage too low Voltage too high Energy too low Energy too high In Fig.
Welding Place the prepared gun on the workpiece so that the whole basis of the ceramic ferrule or supporting tube touches the surface of the workpiece. In so doing, the piston is pushed back by the length of the protrusion, and the tension spring is tightened.
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Bending by = 60 with a hammer or an affixed pipe (for leverage). Result satisfactory, if the welding zone or the heat affected zone shows no cracks or breakages Figure 9: Carrying out a bend test Chart 2 illustrates the assessment of welding results. Chart 2: Assessment of stud welds Appearance Remarks...
Maintenance of the Welding Power Source Prior to any maintenance operation, the mains plug must be disconnected. In case of a fixed connection the voltage must be cut off, and the cut-off switch secured against unintentional switching on. The housing must not be opened unless the voltage is cut off.
3.11 Shutting-Down After termination of welding the power switch must first be turned off. In case of interruption for any length of time, the appliance should also be disconnected from the mains (i.e. by pulling out the plug). Never use the mains plug in lieu of a switch, i.e.
Remedies for Malfunctions Error signals are shown in plain text; with the word “error” in the first line. The error descriptions will then be listed in the following lines. If more than three types of error occur simultaneously, the display screen will temporarily change to show a complete list of errors diagnosed.
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Malfunction Cause Remedy Welding results un- After operating the gun for a longer period, scattering in Function of gun irregular reliable (sometimes the lift will increase. Generally, it will be below the se- good, sometimes lected setting. This means an increase in the number of bad) droplet short-circuits and splashes.
Spare Parts for Welding Power Source 2305i Pos. No. of units Designation Part number hood, laminated 320-0621-000 chassis, laminated and printed (2-parts) 320-0620-000 supporting bracket 320-0917-000 caster with brake 320-0294-000 fixed roller 320-0183-000 handle 320-0050-000 eye bolt 320-0916-000 power switch 325-0309-000 power connection cable 4×16mm², 5m...
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Pos. No. of units Designation Part number operating panel 330-5316-000 key pad 330-0146-000 control board HZG 11A 330-5306-000 control board T 42 330-0303-000 control board HZG 14 330-5281-000 control board TD 2 330-5335-000 control board VPIQ 1 330-5282-000 control board TB 3 330-5285-000 control board NF 2 330-5283-000...
Spare Parts for Stud Welding Guns CLASSIC Spare parts list gun series SK 14 and SK 15 Part-no. Item Description SK 14 SK 14-ISO SK 14 short SK 15 welding gun body 322-0601-000 322-0601-000 322-0604-000 322-0605-000 lower gun handle 322-0597-000 322-0597-000 322-0597-000 322-0597-000...
Spare parts list guns K 22, K 22-D, K 24, K 26 Part Number Pos. Designation K 22 K 22-D K 24 K 26 gun body 322-6051-000 322-6051-000 322-6050-000 322-6096-000 handle cover 322-0075-000 322-0075-000 322-0074-000 322-0074-000 mounting plate with guide bushes 322-6045-000 322-6045-000 322-6045-000 322-6022-000 piston cylinder...
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Part Number Pos. Designation K 22 K 22-D K 24 K 26 welding cable 2 m, 120 mm² without plug, with protective conduit 329-5225-000 29a welding cable 2 m, 50 mm² with plug and protective conduit 329-5217-000 329-5217-000 29a welding cable 2 m, 95 mm² with plug and protective conduit 329-5224-000 29a welding cable 2 m, 120 mm²...
Cable Spare Part List Pos. Designation Part No. welding and control cable extensions 10 m, 50 mm² (complete set) 317-5015-000 welding and control cable extensions 10 m, 70 mm² (complete set) 317-5010-000 welding and control cable extensions 10 m, 95 mm² (complete set) 317-5014-000 welding and control cable extensions 10 m, 120 mm²...
Accessories 12.1 Gun accessories for stud welding guns K 22 to K 26 Figure 43: Gun accessories for shear connectors from 50 mm length Chuck Foot plate Ferrule grip Stud diameter pos. 1 pos. 2 pos. 3 350-0056-000 360-0116-000 355-0031-000 350-0164-000 360-0117-000 355-0033-000...
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Figure 44: Gun accessories for shear connectors up to 50 mm length Screw with Foot plate/ Stud diame- Chuck Washer hexagon ferrule holder Leg pos. 3 pos. 1 pos. 4 socket pos. 2 pos. 5 350-0058-000 360-0164-000 350-0059-000 360-0085-000 350-0059-000 360-0086-000 370-0240-000 370-0055-000...
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Figure 45: Gun accessories for shear connectors in an interior angle Chuck Foot plate Ferrule grip Stud diameter pos. 1 pos. 2 pos. 3 350-0056-000 360-0116-000 355-0263-000 350-0164-000 360-0117-000 355-0043-000 350-0059-000 360-0118-000 355-0044-000 350-0060-000 360-0119-000 355-0268-000 For pos. 4, 5 and 6 see figure 22. Issue 02/2023 ver.
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Figure 46: Gun accessories for threaded studs, tapped studs and plain pins Type PD Type DD Type RD Chuck Ferrule grip Foot plate pos. 1 pos. 3 pos. 2 M 4 x > 20 M 4 x > 20 350-0002-000 355-0001-000 M 5 x >...
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Stud length up to (mm) Required length of Part No. legs (mm) pos. 4 K 22 and K 22-D K 24 K 26 370-0240-000 370-0300-000 370-0400-000 370-0500-000 370-0322-000 370-0323-000 370-0055-000 Washer pos. 5 322-0372-000 Screw with hexagon socket pos. 6 For studs below 12 mm diameter and lengths L >...
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Figure 47: Gun accessories for Insulation pins Stud dimension Chuck pos. 1 Foot plate pos. 2 Supporting tube pos. 3 350-0086-000 (steel) from 3 x 35 350-0087-000 (copper) 370-0103-000 370-0167-000 from 4 x 35 350-0088-000 (steel) from 5 x 35 350-0089-000 (steel) Stud length up to Required length...
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Figure 48: Gun accessories for short cycle stud welding without shielding gas Supporting Stud diameter d Chuck pos. 1 Foot plate pos. 2 Leg pos. 4 tube pos. 3 350-0001-000 350-0002-000 350-0003-000 360-0103-000 370-0240-000 370-0167-000 350-0005-000 350-0007-000 350-0009-000 Washer pos. 5 370-0055-000 Screw with hexagon socket pos.
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Figure 49: Gun accessories for stud welding with shielding gas Supporting tube Foot plate with 3 Chuck with 3 socket head Stud diameter d socket head cap pos. 1 pos. 4 cap screws M 4 x 10 screws M 4 x 10 pos. 2 pos.
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Figure 50: Gun accessories for flat anchors W x T x L (Width x thickness x length) Foot plate Chuck pos. 3 Stopping piece pos. 4 pos. 2 15 x 3 x > 25 360-0096-000 350-6045-000 350-0324-000 15 x 3 x > 35 360-0096-000 350-6045-000 20 x 3 x >...
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Figure 54: Gun accessories for grid fastening Dimension Chuck pos. 1 Ferrule grip pos. 3 Supporting Insulating Foot plate tube pos. 4 tube pos. 5 pos. 2 M 6 x > 20 350-0033-000 355-0002-000 M 6 x > 60 350-0005-000 M 8 x >...
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Figure 55: Gun accessories for welding of Fibrefix-pins Ø 5, Length L Chuck pos. 1 Foot plate pos. 2 Ferule grip pos. 3 Leg pos. 4 370-0240-000 up to L = 160 mm 370-0300-000 up to L = 220 mm 350-0100-000 360-0101-000 355-0002-000...
12.2 Gun accessories for Gun series SK 14 and SK 15 Figure 56: Gun accessories for short-cycle stud welding without shielding gas Stud dimen- Chuck Foot plate Supporting Leg pos. 4 sion (D x L) pos. 1 pos. 2 tube pos. 3 Ø...
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Figure 57: Gun accessories for threaded studs and plain pins Type PD Type DD Type RD Chuck Ferrule grip Foot plate pos. 1 pos. 3 pos. 2 M 4 x > 16 M 4 x > 16 350-0002-000 355-0001-000 M 5 x > 16 M 5 x >...
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Figure 58: Gun accessories for insulation pins Chuck Foot plate Supporting Stud dimension pos. 1 pos. 2 tube pos. 3 350-0086-000 (Steel) from 3 x 35 350-0087-000 (Copper) 360-0012-000 360-0335-000 from 4 x 35 350-0088-000 (Steel) from 5 x 35 350-0089-000 (Steel) Stud length up to Required length of...
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Figure 59: Gun accessories for stud welding with shielding gas (Gun SK 14) Foot plate with 2 Supporting tube with 2 Chuck Stud diameter d socket head cap Leg pos. 4 socket head cap pos. 1 screws M 4 x 10 pos. 2 screws M 4 x 10 pos.
Literature EN ISO 14555 “Drawn arc stud welding of metallic materials“ EN ISO 13918 “Studs and Ceramic Ferrules for Drawn Arc Stud Welding“ DVS-Technical Bulletin 0901 “Stud Welding Procedures for Metals – Overview“ DVS-Technical Bulletin 0902 "Drawn Arc Stud Welding" DVS-Technical Bulletin 0903 “Stud Welding with Tip Ignition“...
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