Plm560 en

Operating Manual Stud welding Gun PLM 560
Please read the operating manual before any operation!
Emhart Teknologies TUCKER GmbH Max-Eyth-Strae 1 D-35394 Gieen Tel.: Fax.: +49 (0) 641 405 0 +49 (0) 641 405-383
E-Mail: [email protected] Internet: www.tucker.de
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Stud welding Gun PLM 560
Table of contents Table of contents:

1. General Information ..............................................................................................5 1.1 Information regarding the operating manual .................................................5 1.2 Limitation of liability ......................................................................................5 1.3 Symbol legend..............................................................................................6 1.4 Copyright protection .....................................................................................7 1.5 Warranty .......................................................................................................8 1.6 Service..........................................................................................................8 2. Safety....................................................................................................................9 2.1 Responsibility of the operating company ......................................................9 2.2 Operating Personnel...................................................................................10 2.2.1 Requirements...................................................................................10 2.2.2 Instruction ........................................................................................10 2.3 Intended Use ..............................................................................................11 2.4 Personal protective equipment ...................................................................12 2.5 Special risks ...............................................................................................13 2.6 Safety installations......................................................................................13 3. Technical Specifications......................................................................................14 3.1 General Specifications................................................................................14 3.2 Connected loads.........................................................................................14 3.3 Accessories ................................................................................................14 4. Preface: Stud Welding ........................................................................................15 5. General Description ............................................................................................16 6. Connection and Installation.................................................................................17 6.1 Overview PLM 560 .....................................................................................17 6.2 Connection cable package .........................................................................18 6.3 Layout welding system ...............................................................................19 7. Weld Gun Adjustments .......................................................................................20 7.1 Software Angularity switch..........................................................................20 8. Stud welding instructions ....................................................................................24 8.1 Before weld process start ...........................................................................24 8.2 Stud welding process description ...............................................................25 8.3 Notes on working with protective gas .........................................................26
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Table of contents
9. Transport, packaging and storage ......................................................................27 9.1 Security advice for the transport .................................................................27 9.2 Transport check..........................................................................................27 9.3 Storing ........................................................................................................27 10. Maintenance .......................................................................................................28 10.1 Safety .........................................................................................................28 10.2 Maintenance schedule................................................................................28 10.3 Maintenance works.....................................................................................30 10.3.1 PLM 560 for standard-, large flange - and step studs ....................31 10.3.1.1 Replacing the stop screw ................................................31 10.3.1.2 Replacing the flashshield ................................................31 10.3.1.3 Replacing the collet .........................................................31 10.3.1.4 Replacing the swivel nut..................................................32 10.3.2 PLM 560 for large flange studs with cap or collar nut ....................32 10.3.2.1 Replacing the stop bolt....................................................32 10.3.2.2 Replacing flashshield ......................................................33 10.3.2.3 Replacing collet...............................................................33 10.3.2.4 Replacing swivel nut .......................................................33 11. Refitting the PLM 560..........................................................................................34 11.1 PLM 560 for standard-, large flange - and step studs.................................35 11.1.1 Replacing the collet........................................................................35 11.1.2 Attachment of the stop bushing......................................................35 11.2 PLM 560 for large flange studs with cap or collar nut .................................36 11.2.1 Replacing the collet........................................................................36 11.3 Refitting tables explanation.........................................................................37 11.4 Refitting tables for the weld gun versions PLM560.00.02/03/04 .................38 11.5 Refitting tables for the weld gun versions PLM560.00.11/12/13 .................42 12. Exploded views ...................................................................................................47 12.1 Kit barrel housing........................................................................................47 12.2 Kit Gun handle............................................................................................48
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General Information 1. 1.1 General Information Information regarding the operating manual
This operating manual contains important information regarding the handling of this device. The compliance with all security advisories and operation instructions is a precondition for a safe operation. Furthermore the local accident prevention regulations and the general safety regulations effective for the application area of the device have to be observed. Please read the operating manual carefully before any operation! It is a part of the product and has to be stored in an accessible location in the direct vicinity of the device for use by the appropriate personnel.
1.2
Limitation of liability
All instructions and information in this operating manual have been compiled in consideration of the valid standards and regulations, the state of the art as well as our experience of many years. The manufacturer assumes no liability for damages due to: Non-observance of the operating manual. Not intended use. Employment of unskilled staff. Arbitrary rebuilding. Technical modifications. Use of non-licensed replacement parts.
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General Information 1.3 Symbol legend
The warning notices in this operation manual are indicated by symbols. The notes commence with a signal word which expresses the extent of the danger. Observe the notes and act with caution to avoid accidents and damage to persons and property.
DANGER! points to a directly dangerous situation which can lead to death or severe injuries if it is not avoided.
WARNING! points to a possibly dangerous situation which can lead to death or severe injuries if it is not avoided.
CAUTION! points to a possibly dangerous situation which can lead to slight injuries if it is not avoided.
CAUTION! points to a possibly dangerous situation which can lead to damage of property if it is not avoided.
Tips and recommendations
NOTE! highlights useful tips and recommendations as well as information for an efficient and failure-free operation.
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General Information
Special security advisories In order to draw attention to special dangers, the following symbols are used in connection with security advisories: DANGER! Danger to life by electric current! indicates perilous situations by electric current. Disregarding of the security advisories can lead to severe injuries or death. The operations which need to be carried out may only be executed by electronic technicians.
1.4
Copyright protection
Keep the operating manual in confidence. It is solely intended for the person using this device. The surrender of the operating manual to a third party without a written permission of the manufacturer is forbidden. NOTE! The contents, texts, drawings, pictures and other illustrations are copyrighted and are subject to the industrial property rights. Each misuse is indictable. Any kind of copying, - also in extracts - as well as the utilisation and/or notification of the content is forbidden without a written declaration from the manufacturer. Non-compliances obligate to damages compensation. Further claims remain reserved.
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General Information 1.5 Warranty
The PLM 560 stud welding gun is covered by a one-year warranty against defects in material and manufacturing. Damages incurred through improper handling are not included. The warranty covers a cost-free replacement of the defective component. Liability for incidental and consequential damage is excluded. Warranty is void if the unit is repaired by unauthorized personnel. In case of a defect the rejected unit must be sent to a Tucker representative or directly to the manufacturer. All warranty claims arising outside of the Federal Republic of Germany will be addressed by an authorized local Tucker representative according to the individual country-specific laws and regulations.
1.6
Service
Our service department is available for technical support. Information about the responsible contact person is anytime available via telephone, fax, and email or via the Internet, please see manufacturer address on page 2.
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Safety 2. Safety
This paragraph gives a review about all important safety aspects for an optimal protect of the staff as well as for the safe and failure-free operation. Disregard of the operating instructions and security advices mentioned in this manual could lead to serious dangers.
2.1
Responsibility of the operating company
The welding gun is used industrially. Therefore the operating company of the unit is liable to the legal obligations of operational safety. In addition to the operational safety advices in this operating manual the safety-, accident prevention- and environmentalism regulations valid for the area of application need to be observed. Please consider particularly the following: The operating company has to inform himself about the valid industrial safety regulations and determine additional dangers in an assessment of hazards which occur by the special working conditions on the site of the unit. He has to implement these for the operation of the unit in the form of operating instructions. The operating company has to provide the staff with the required protective equipment.
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Safety 2.2
2.2.1
Operating Personnel
Requirements
WARNING! Risk of injury on insufficient qualification! Improper handling can lead to serious damage to persons and property. Therefore: - Special tasks should only be executed by persons named in the respective chapters of this manual. - If in doubt call in specialists.
The following qualifications for different areas of operations are named in the operating manual: Instructed person has been informed about the tasks assigned and possible dangers of improper execution of an instruction by the operating company. Qualified personnel is able to execute the required tasks due to professional education, knowledge and experiences.
2.2.2
Instruction
The staffs have to be instructed regularly by the operating company. For a better traceability the implementation of the instruction should be recorded.
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Safety 2.3 Intended Use
The stud welding gun was designed exclusively for the intended use mentioned in this manual. The PLM 560 stud welding gun was designed as a manually-operated weld tool exclusively for drawn arc stud welding in closed industrial areas.
WARNING! Risk by not intended use! Every not intended use and/or different use can lead to dangerous situations. Therefore: - The welding gun only to be used in connection with control- and power units of the DCE/TMP series of Tucker. The welding gun may neither be used in the presence of explosive material nor in damp conditions. Only those weld studs will be used for which the PLM stud welding gun is equipped.
An electro-magnetically interference-free operation of the PLM 560 stud welding gun can be guaranteed by complying with the specifications in chapter 6 "Connection and installation"!
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Safety 2.4 Personal protective equipment
At work wearing personal protective equipment is essential to minimize the risks for the health. During working time always wear the required protective equipment for the respective work. Observe the signs regarding the personal protective equipment which exist in the working area. Strictly to wear at working on the PLM: Protective glasses For the protection of the eyes from foreign bodies.
Strictly to wear
Wear on welding Protective glasses for welding of protective level 3 For the protection of the eyes from UVA/B/C radiation and weld splatters.
Protection clothes Wear flame resistant clothes protection of weld splatters.
for
the
Hardhat A hardhat is to be worn when welding overhead for the protection of falling weld splatters.
Gloves For the protection of the hands from UVradiation and weld splatters.
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Safety 2.5 Special risks
The residual risks which arise from the hazard analysis are described in the following chapter. Please consider the below mentioned security advices and warnings in the following chapters of this manual to reduce health hazards and to avoid dangerous situations. Electric current DANGER! Danger of life by electric current! Contact with components under current is perilous. Damage of the electrical isolation or of several components can be perilous. Therefore: - On damages of the isolation cut-off immediately the power supply and induce repairing. - Work on the electric installation may only be executed by specialists for electronics. - Do not connect or disconnect the live plug connector. - During all work on the electric installation you have to switch it death and test if it is zero-potential. - The collet is electrified during welding and therefore may not be touched. - On maintenance- and corrective maintenance work disconnect the PLM 560 from the control cabinet.
Under no circumstances are persons using a cardiac pacemaker to operate or remain in the vicinity of stud welding machines.
2.6
Safety installations
The PLM 560 stud welding gun is designed for the application within an installation. It has no autonomous emergency-stop-function.
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Technical Specifications 3. 3.1 Technical Specifications General Specifications

Specification
Weight complete Length, depending flashshield Width Height System of protection Protected against solid objects until 12 mm.
Value
5,8 appr.330 68 240 IP 21
Unit
kg mm mm mm Protected against vertical falling water drop
Operating temperature Stocking temperature Relative humidity of air Working position Noise emission Vibration value Electromagnetic compatibility Sound pressure level Effective acceleration value
15 - 40 15 - 40 0 - 95 Indefinite < 75 < 2,5
C C % dB (A) m/s2
The PLM 560 stud welding gun has been tested following the norm DIN EN 60 974-10
3.2
Connected loads
Specification
Driving Voltages Drawing of current max.
Electrical
Value
24/140 2,5
Unit
V DC A
3.3
Accessories
Specification
Socket wrench for swivel nut Setting gauge for lift Horizontal fastening
Order number
M110 014 M111 012 M181 414
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Preface: Stud Welding 4. Preface: Stud Welding
In almost all technological disciplines where continuous metal work surface fastenings are required, light arc stud welding has become more and more important. Decisive factors in the growing acceptance of light arc stud welding are the wide range of possible applications and the increasing demand for efficiency and rationalization in todays business environment. Tucker has chosen to perform light arc welding using a drawn arc welding ignition mechanism. This technology offers highly repeatable piece-to-piece accuracy, works quietly and achieves a consistently high quality level. Reliability and process safety are the hallmarks of the welding process, which essentially consists of stud movement combined with synchronous welding current. The precise adjustment of these process elements guarantee the quality and reproduce ability of Tucker unit welding results in automated, in semi-automated and also in manual operation.
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General Description 5. General Description
The manually-supplied PLM 560 weld gun was designed for welding weld studs onto metal work surfaces. It operates on a short-term drawn arc welding ignition mechanism. The PLM 560 represents a further development of the weld head technology, which is well proven in the difficult welding environment, i.e. the advantages of a weld head were combined with the flexibility of a weld gun. Furthermore the PLM 560 was equipped with a maintenance-free, cylindrical slide bearing. This is mainly important for welds where exact control of the mechanical weld parameters is required. Furthermore the PLM 560 is equipped with a linear motor, with which the plunge movement of the stud can be specified precisely. The weld results, particularly with aluminium, are improved as a result. The stud movement of the PLM 560 is monitored through a distance measuring system, which is able to measure exactly the stud lift as well as the plunge depth of the stud into the melt. In order to protect the weld zone against oxygen influences from the outside the PLM 560 has a protective gas flash shield. This feature improves the quality of welding for all studs especially for aluminium studs. The PLM 560 has a light emitting diode via which the user can verify the rightangle approach of the gun before issuing the start command, to assure that the studs are always welded at a right angle onto the work surface. In order to minimize fatigue while working with the weld gun, the PLM 560 should be mounted to a balancer during operation. The corresponding holding device on the backside is already provided for. A mounting for horizontal welding processes can be retrofitted. The multicoupling system of the electrical and pneumatic supply cables allows a fast and simple replacement of the weld gun during different welding operations or during refitting.
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Connection and Installation 6. Connection and Installation

CAUTION! Before connecting the PLM 560 disconnect the control- and power unit from the power supply!
6.1
Overview PLM 560

6 7
1 2
3
1. Flashshield 3. Cable package 5. Type plate 7. Holding device horizontal (Option) 2. 4. 6. 8. Start button Gun handle Holding device vertical (Standard) Support for flashshield
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Connection and Installation 6.2 Connection cable package
The electrical and pneumatic connection cables of the cable package are securely fixed at the PLM 560 and are to be connected to the control cabinet via the multicoupling plug. (See chapter 6.3)
NOTE! Install the power supply cables according to the layout in chapter 6.3. The welding and ground cables are to be laid out in their whole length. This avoids inductive bypasses and line breaks!
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6.3
Control and power unit
PLM 560 Control cabinet
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Layout welding system
Cable package
Control cable Weld cable Measurement line
Ground cable Ground-measurement line
Connection and Installation
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Adjustments 7. 7.1 Weld Gun Adjustments Software Angularity switch
The stud welding gun touching the work piece, the weld stud is pushed backwards by the mechanic of the gun. After the flash shield has been straightly attached, the switch point for the angularity switch can be calibrated. By the + and - tolerance it can be determined how much slope the gun may have (angular deviation), resp. how much deviation by a convex or concave work piece form is allowed. Work principle: The Software-angularity switch is based on the measurement of the stud length.
Stud length
Due to the different path measurement for the feeders SFLM and ETF, there are differences in calibrating. Control and power unit TMP with feeder SFLM:
Angularity switch detection ---------------------------------------Feeder number.........:# Stud load.............:######### Process...............:######### Switching point.......:#####mm Checkup...............:######### Difference............:#####mm Switching point +tol...:#####mm Switching point tol...:#####mm ---------------------------------------<-> <1-5> <+,-> <F1-F6> <ENTER> <ESC>
Teach software angularity switch: 1. Select menu Extended functions teach angularity switch. 2. Quote Feeder number. 3. Select Stud load to feed a new stud.
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Adjustments
4. Hold the gun freely in the air so that the stud can reach the front position.
5. Select Process The green LED is flashing.
LED
6. Press button Start weld The path measurement system is set to zero Green LED is flashing faster. 7. Attach the weld gun on the sheet metal and hold it exactly upright. SOW is generated green LED is flashing more slowly again. 8. Press button Start weld green LED is flashing faster again Measuring value is adopted and memorized. When Switching point, the current measuring value is displayed at the control panel. Check software angularity switch 1. Select menu Extended functions Teach angularity switch. 2. Insert Feeder number. 3. Select Stud load to feed a new stud. 4. Hold the gun freely in the air so that the stud can reach the front position. 5. Select Check-up Now the green LED is flashing. 6. Press button Start weld The path measurement system is set to zero Green LED is flashing faster. 7. Attach the weld gun on the sheet metal and hold it exactly upright. SOW is generated green LED is flashing slowly again. 8. Press button Start weld green LED is flashing faster again The measured value will be compared with the value saved. When Difference, the deviation from the memorized measuring value will be displayed at the control panel. The accuracy of the switch point is adjusted in the menu Extended functions Teach angularity switch under point Switching point Switching point
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+ tol..:##### mm - tol..:##### mm.

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Adjustments
This value must be chosen in such a way that it compensates the length tolerance of the studs as well as the tolerances of the work piece and that it guarantees the angularity of the welding. Control and power unit DCE with feeder ETF:
Teach angularity Outlet: Teach position Value (ref)..... ##### mm Check position Difference...... ##### mm Tolerance +/-... ##### mm
Teach software angularity switch: 1. Select Stud load to feed a new stud into the gun. 2. Select menu Outlet programming for the feeder to be programmed. 3. Select Teach angularity. 4. The green LED of the gun is now flashing with slow frequency. 5. Change to Teach position via arrow key . 6. Attach the pistol on the sheet metal and hold it exactly upright. SOW is generated green LED is still flashing with slow frequency. 7. Press button Start weld green LED is flashing with higher frequency. 8. By unclasping the button Start weld, the measuring value is adopted in the control panel and displayed in the line Value. 9. By the button F5 the menu is quit and the reference value is adopted in the original program. A storage is not effected until the menu Programming weld outlet is quit by button ENTER!
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Adjustments
The calibrating of the angularity switch is not only possible outlet-related, but also program-related. Precondition: The angularity switch must be activated in the outlet programming. Then there are the following possibilities in the weld program: - Angularity switch: Prog. Program-related reference value of the angularity switch, newly calibrate here! - Angularity switch: Outlet Outlet-related reference value of the angularity switch, already calibrated in the original programming. - Angularity switch: No The angularity switch is deactivated for that weld program. Check software angularity switch 1. Select Stud load (e.g. via button BF of the PLM) to feed a new stud into the gun. 2. Select menu Outlet programming for the feeder number. 3. Select Teach angularity. 4. The green LED of the gun is now flashing with slow frequency. 5. The choice is now set to Check position. 6. Attach the weld gun on the sheet metal and hold it exactly upright. SOW is generated green LED is still flashing with slow frequency 7. Press button Start weld green LED is flashing with higher frequency. 8. By unclasping the button Start weld, the measuring value is adopted in the control panel and in the line Difference, the deviation regarding the reference value is displayed with the correct signs. The accuracy of the switch point is adjusted in the menu for calibrating the angularity switch under point Tolerance +/-. This value must be chosen in such a way that it compensates the length tolerance of the studs as well as the tolerances of the work piece and that it guarantees the angularity of the welding.
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Stud Welding Instructions 8. 8.1 Stud welding instructions Before weld process start
NOTE! The following stud welding instructions must be observed before the welding process is started through the start command of the weld gun! The welding position must be prepared such that there is a level surface with a diameter of approx. 40 mm for the fitting of the gun available. The optional mounting bushing should be implemented when using a template. In order to guarantee for a high welding quality, the work surface, particularly in the direct welding zone, should be mostly free of any kind of impurities. The weld gun must be operated such that it always contacts the work surface at an angle of 90. It must be guaranteed during the welding process that the weld gun position as well as the position of the work surface remains unchanged. If different welding procedures must be performed on one work piece those must take place at different times. Radiofrequency weldings must be performed in a separate location and must be supplied from a separate power circuit. In order to have optimum weld quality the grounding cable to the work piece must be installed symmetrically. Elimination of unwanted light arcs on pressure spring retention elements will be achieved by a Tucker grounding contact (Order no.: M108 972) connection. Vibrations of thin-wall work pieces can be avoided by using a weld location thrust bearing made from copper, brass or aluminium. Weld templates must be made from non-magnetic material and manufactured such that they can not get out of place during the welding process.
NOTE! The basic stud welding unit requirements can be read from the Tucker installation guideline!
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Stud welding instructions 8.2 Stud welding process description
The mechanical process of stud movement along with the respective electrical processes are described in the reference drawing below.
Short phase (SOW) Lift- and precurrent phase Welding phase Plunging phase
Welding current Weld stud distance
Light arc tension
1. The required condition for the welding process is contact of the weld stud with the work surface (SOW), so that when the start command has been given the weld circuit will be electrically shorted via stud and work piece. 2. After stabilization of the pilot current the linear motor removes the stud from the work piece in accordance with a specified, programmed curve and the pilot current light arc is ignited. The pilot current light arc is needed for igniting the main light arc. 3. After the pilot current phase is terminated the main welding current is switched on, which will intensify the light arc energy such that the stud front edge and the work surface are melted. 4. While the light arc creates a melt on the work piece and on the front face of the stud, the linear motor is reversed. By means of a controlled, linear movement the stud is pressed into the melt. The linear motor stays in this position in keeping with the programmed holding line. 5. With the plunging of the stud into the melt, the light arc extinguishes so that the homogenous melt coagulates and the weld gun can be removed from the stud when the welding current is switched off again. Remark: The welding cycle is terminated with the removal of the weld gun from the stud and can be repeated after a new stud has been reefed.
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Stud welding instructions 8.3 Notes on working with protective gas
In the protective gas welding of aluminium studs, the atmosphere is expelled from the welding area by the protective gas so as to prevent unwanted reactions between the materials and the ambient air. Thanks to the use of protective gas, the fusion melting characteristics of welding studs and work piece are improved and the formation of pores is reduced. It also has a positive effect on the welding bead and on the form of the fusion penetration. In accordance with DIN EN 439 Protective gases for welding, the use of pure argon (Ar 99.99) is advised for welding aluminium studs. The protective gas supply must be made available by the user. WARNING! When selecting gas hoses and connection fittings for the protective gas supply, care must be taken that these are suitable for the customer specific protective gas used. The supply of protective gas to the welding gun is regulated via a separate Tucker gas module. The electrical control signal for protective gas operation is always issued by the welding device. The intervals in the gas feed comprise advance- and after-flow phases. In the advance-flow phase the welding area is shrouded in protective gas. In the afterflow phase chemical reactions are prevented during cooling.
WARNING! Please note that when welding studs using protective gas, it is absolutely essential that the safety precautions specified hereinafter be observed. Only gas bottles equipped with a pressure reducer and a pressure gauge may be used. The pressure reducer must be selected according to the type of gas used and the operating conditions, which apply. Prior to extended interruptions to the work or after consuming the contents of the bottle, the pressure reducer must be closed.
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Transport, packaging and storage 9. 9.1 Transport, packaging and storage Security advice for the transport
Improper transport
CAUTION! Damages caused by improper transportation. Improper transport could cause serious damage of property. Therefore: Necessary transports have to be carried out in that way that neither dust nor liquids could ingress into the interior of the device. Avoid shocks and heavy vibrations
9.2
Transport check
The PLM 560 stud welding gun has been subjected to thorough testing and suitably packed for transport before despatch. Upon delivery, the equipment, including accessories, should be checked for completeness and damage. On externally visible transport damage, proceed as follows: Do not accept the delivery or only accept with reservation. The manufacturer or the transport company responsible is to be notified immediately. NOTE! Please regard the national regulations on disposal of packaging material.
9.3
Storing
If the PLM 560 is not installed in the welding system immediately after delivery, it is to be ensured that neither dust nor liquid can penetrate inside the equipment during interim storage. Avoid any knocks, vibrations, frost, great temperature and moisture fluctuations.
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Maintenance 10. 10.1 Maintenance Safety

The maintenance work described can be executed by the operator, if it is unless it is marked differently. Some maintenance work may only be executed by specially trained experts. Maintenance work on the electric installation basically may only be executed by specialists for electronics.
Personnel
10.2
Maintenance schedule
The maintenance work essential for an optimal and failurefree operation is described in the following chapters. In case of detection of an increased abrasion during regular checks, shorten the required maintenance intervals accordingly to the actual signs of abrasion. If you have questions concerning maintenance work and intervals contact the manufacturer, see service address on page 2.
Intervals Daily
Wearing Parts Collet Flash shield Stop screw/Stop bolt Cable package Swivel nut Overhaul
Maintenance Instructions Check tension force and clean Check for firm fit and remove weld splatters Check for abrasion Clean and check for abrasion Check for firm fit Complete check for wear
Weekly Monthly Annually
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Maintenance
Flashshield support Flashshield
Stop bolt Collet Swivel nut
Cable package
NOTE! It is recommended to stock the above mentioned wearing parts.
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Maintenance 10.3 Maintenance works
The maintenance works for the different PLM 560 versions are described in the following sections. If the installation of replacement parts becomes necessary, maintenance has to be performed consulting the attached explosion drawings.
NOTE! For all replacement work, reassembly of the replaced parts is to be performed in opposite sequence of the disassembly.
Implementation by specially trained experts. Tools required: Allen key SW2 Socket wrench for swivel nut (see chapter 3) Open-end wrench SW 8 Open-end wrench 17 (swivel nut)
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Maintenance
10.3.1 PLM 560 for standard-, large flange - and step studs
Flashshield support Flashshield Stop screw
Collet Swivel nut Adjustment nut Counter nut
10.3.1.1 Replacing the stop screw

1. Turn the flash shield support counter clockwise manually until limit stop and remove it completely including flash shield. 2. Unscrew the swivel nut with the socket wrench (Accessories). 3. Pull the collet including stop screw off manually completely. 4. Unscrew the stop screw from the collet with an open-end wrench SW 8. 5. Replace the stop screw.
10.3.1.2 Replacing the flash shield

1. Loosen the M 4 fillister head screw with an Allen key on the flash shield holder. 2. Release the flash shield with a slight tap of a hammer (if necessary) on the screw head and replace the flash shield.
10.3.1.3 Replacing the collet

1. Turn the flash shield support counter clockwise manually until limit stop and remove it completely including flash shield. 2. Unscrew the swivel nut with the socket wrench (Accessories).
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Maintenance
3. Pull the collet including stop screw off manually completely. 4. Unscrew the stop screw from the collet with an open-end wrench SW 8 and replace the collet.
10.3.1.4 Replacing the swivel nut

1. Turn the flash shield support counter clockwise manually until limit stop and remove it completely including flash shield. 2. Unscrew the swivel nut with the socket wrench (Accessories) and replace the swivel nut.
10.3.2
PLM 560 for large flange studs with cap or collar nut
Stop bolt Collet Extension Swivel nut
10.3.2.1 Replacing the stop bolt

1. Turn the flash shield support counter clockwise manually until limit stop and remove it completely including flash shield. 2. Unscrew the swivel nut including collet and extension with the socket wrench (Accessories). 3. Unscrew the collet manually from the extension. 4. Unscrew the stop bolt from the extension with an open-end wrench SW 8 5. Replace the stop bolt.
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Maintenance
10.3.2.2 Replacing flash shield
1. Loosen the M 4 fillister head screw with an Allen key on the flash shield holder. 2. Release the flash shield with a slight tap of a hammer (if necessary) on the screw head and replace the flash shield.
10.3.2.3 Replacing collet

1. Turn the flash shield support counter clockwise manually until limit stop and remove it completely including flash shield. 2. Unscrew the swivel nut with the socket wrench. 3. Replace the collet.
10.3.2.4 Replacing swivel nut

1. Turn the flash shield support counter clockwise manually until limit stop and remove it completely including flash shield. 2. Unscrew the collet manually from the extension. 3. Replace the swivel nut.
NOTE! After the completion of any maintenance or repair work, the weld gun settings are to be checked. For instructions please see the corresponding chapters of this manual.
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Maintenance 11. Refitting the PLM 560
For welding different weld studs the weld gun must be refitted accordingly. The required refitting parts are listed in the refitting tables. Remark: The collet can be composed of different components depending on the stud type: Collet with stop screw and adjustment and counter nuts. Collet with stop bolt. Collet with extension.
Refitting Instructions Reassembly of the replacement parts is to be performed in opposite sequence of the disassembly. Update the type label on the PLM 560 after refitting. Check the settings of the PLM 560 after refitting.
!
Ordering Instructions:
CAUTION! Refitting works are always to be performed in a workshop.
Read the current stud dimensions from the adhesive label on the weld gun housing ( [mm] / l [mm]). Search for the required dimensions in the refitting table. Then compare the order numbers of the available components with the order numbers of the required components. If the M-numbers differ, those components are to be ordered indicating the name and amount.
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Refitting 11.1 PLM 560 for standard-, large flange - and step studs
Flashshield support Flashshield Stop screw
Collet Swivel nut Adjustable nut Counter nut
11.1.1
Replacing the collet
1. Turn the flash shield support counter clockwise manually until limit stop and remove it completely including flash shield. 2. Unscrew the swivel nut with the socket wrench (Accessories). 3. Pull the collet including stop screw off manually. 4. Insert a weld stud in the required collet. The weld stud must protrude by 2,5 mm above the collet. 5. Screw the stop screw into the collet until it contacts the weld stud. 6. Tighten the counter nut. 7. Assemble collet, swivel nut and flash shield holder.
11.1.2
Attachment of the stop bushing
Weld studs of the same dimension, with the same flange thickness but of different lengths can be welded by using a stop bushing. 1. Turn the flash shield support counter clockwise manually until limit stop and remove it completely including flash shield. 2. Unscrew the swivel nut with the socket wrench (Accessories). 3. Unscrew the stop screw as far as possible. 4. Mount the collet. 5. Attach the stop bushing to the collet. 6. Assemble swivel nut and flash shield holder.
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Refitting 11.2 PLM 560 for large flange studs with cap or collar nut
Stop bolt Collet Extension Swivel nut
11.2.1
Replacing the collet
1. Turn the flash shield support counter clockwise manually until limit stop and remove it completely including flash shield. 2. Unscrew the swivel nut with the socket wrench (Accessories). 3. Pull the collet including stop bolt off manually. 4. Screw the stop bolt into the new collet. 5. Assemble collet, swivel nut and flash shield holder.
NOTE! After the completion of any maintenance or repair work, the weld gun settings are to be checked. For instructions please see the corresponding chapters of this manual.
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Refitting 11.3 Refitting tables explanation

The following refitting tables details information describing which components are to be used with a respective weld stud. Table Explanation: Stud dimension x length [mm] Flash shield The weld stud dimensions define which components of the stud receiver must be used. The flash shield dimension depends on the weld stud diameter. The flash shield with the indicated order number must be used. The collet depends on the weld stud dimensions. The collet with the indicated order number must be used. If required, an extension and/or a stop bolt with the indicated order number are to be used. If required, a stop screw with the indicated order number must be used. If a stop screw is required, an adjustment nut and a counter nut with the indicated order number must be used. If required, a stop bolt with the indicated order number must be used. Use a swivel nut with the indicated order number If required, a stop bushing with the indicated order number can be used. Thus weld studs with the same dimensions, the same flange thickness and of different lengths can be welded.
Collet
Extension
Stop screw Adjustment nut Counter nut Stop bolt
Swivel nut Stop bushing
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Refitting tables 11.4 Refitting tables for the weld gun versions PLM560.00.02/03/04
Standard studs
Stud dimension x length [mm] Flashshield 25 Flashshield 28 Collet Stop screw Adjustment nut Counter nut Swivel nut Stop bushing
3 x 5 up to 22
M 150 401 M 150 402 M 150 401 M 150 402 M 150 401 M 150 402 M 150 401 M 150 402 M 150 401 M 150 402 M 150 401 M 150 402 M 150 401 M 150 402 M 150 401 M 150 402 M 150 401 M 150 402 M 150 401 M 150 402
M 150 423 M 150 423 M 150 424 M 150 424 M 150 421 M 150 421 M 150 426 M 150 426 M 150 428 M 150 428
3 x 23 up to 38
4 x 5 up to 22
4 x 23 up to 38
5 x 5 up to 22
5 x 23 up to 38
6 x 5 up to 22
6 x 23 up to 38
8 x 5 up to 22
8 x 23 up to 38
M 150 491 M 150 258 M 150 259 M 150 492 M 150 258 M 150 259 M 150 491 M 150 258 M 150 259 M 150 492 M 150 258 M 150 259 M 150 491 M 150 258 M 150 259 M 150 492 M 150 258 M 150 259 M 150 491 M 150 258 M 150 259 M 150 492 M 150 258 M 150 259 M 150 491 M 150 258 M 150 259 M 150 492 M 150 258 M 150 259
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Refitting tables
Large flange studs without cap
Stud dimension x length [mm] Flashshield 28 Collet Stop screw Adjustment nut Counter nut Swivel nut Stop bushing
6x6 up to 22F13
M 150 402
M 150 426 M 150 426 M 150 426 M 150 426
M 150 266 M 150 258 M 150 259 M 150 265 M 150 258 M 150 259 M 150 266 M 150 258 M 150 259 M 150 265 M 150 258 M 150 259
M 150 251 M 063 412 M 150 251 M 063 412 M 150 251 M 063 412 M 150 251 M 063 412
6x23 up to 38F13
M 150 402
6x6 up to 22F14
M 150 402
6x23 up to 38F14
M 150 402
Large flange studs with plastic cap

Stud dimension x length [mm] Flashshield 30 Collet Extension Swivel nut
14 x 20,5
M 150 405
M 150 436 M 150 488 M 150 432 M 150 488 M 150 433 M 150 488 M 150 438 M 150 488
M 150 253
14 x 21
M 150 405
M 150 253
14 x 23
M 150 405
M 150 253
SWB 412
M 150 405
M 150 253
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Refitting tables
Large flange studs with Cap- or Collar Nut
Stud dimension x length [mm] Flashshield 30 Collet Extension Stop screw Swivel nut
12,5 x 17BM
M 150 405
M 150 436 M 150 488 M 150 499 M 150 432 M 150 488 M 150 490 M 150 433 M 150 488 M 150 427 M 150 488 M 150 482
M 150 253
12,5 x 21HM
M 150 405
M 150 253
14 x 19BM
M 150 405
M 150 253
14,5 x 25HM
M 150 405
M 150 253
T - Studs
Stud type Flashshield 25 Collet Swivel nut
SWB 09
M 150 401
M 150 429
M 150 252
SWB 10/11
M 150 409
M 150 430
M 150 251
SWB 366
M 150 401
M 150 435
M 150 252
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Refitting tables
Step studs
Stud type Flashshield 25 Collet Stop screw Adjustment nut Counter nut Swivel nut
SWB 403/468
M 150 401
M 150 426 M 150 421
M 150 495 M 150 258 M 150 259 M 150 496 M 150 258 M 150 259
M 150 251
M 150 251
SWB 439/481
M 150 401
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Refitting tables 11.5 Refitting tables for the weld gun versions PLM560.00.11/12/13
Standard studs
3 x 5 up to 20
M 150 501
3 x 21 up to 32
M 150 501
3 x 33 up to 41
M 150 501
3 x 42 up to 56
M 150 501
4 x 5 up to 20
M 150 502
4 x 21 up to 32
M 150 502
4 x 33 up to 41
M 150 502
4 x 42 up to 56
M 150 502
5 x 5 up to 20
M 150 503
5 x 21 up to 32
M 150 503
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Refitting tables
Standard studs
5 x 33 up to 41
M 150 503
5 x 42 up to 56
M 150 503
6 x 5 up to 20
M 150 504
6 x 21 up to 32
M 150 504
6 x 33 up to 41
M 150 504
6 x 42 up to 56
M 150 504
8 x 5 up to 20
M 150 505
8 x 21 up to 32
M 150 505
8 x 33 up to 41
M 150 505
8 x 42 up to 56
M 150 505
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Refitting tables
T - Studs
Stud type Flashshield 28 Flashshield 25 Flashshield 19 Collet Swivel nut
SWB 09
M 150 407 M 150 415 M 150 407 M 150 415 M 150 418
M 150 326
M 150 252 M 150 251
SWB 10/11
M 150 507
Step studs
Stud type Flashshield 28 Flashshield 25 Flashshield 19 Collet Stop screw Adjustment nut Counter nut Swivel nut
SWB 403/468
M 150 407 M 150 415 M 150 407 M 150 415 M 150 418
M 150 504
M 150 500 M 150 258 M 150 259 M 150 498 M 150 258 M 150 259
M 150 251 M 150 251
SWB 439/481
M 150 503
X-Mas tree Studs

Stud type Flashshield 25 Collet Stop screw Adjustment nut Counter nut Swivel nut
SWB 463
M 150 415
M 150 325
M 150 267 M 150 258 M 150 259
M 150 252
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Refitting tables
5x5 up to 20F13
M 150 503
5x21 up to 32F13
M 150 503
5x33 up to 41F13
M 150 503
5x42 up to 56F13
M 150 503
6x6 up to 20F13
M 150 504
6x21 up to 32F13
M 150 504
6x33 up to 41F13
M 150 504
6x42 up to 56F13
M 150 504
6x6 up to 20 F14
M 150 504
6x21 up to 32F14
M 150 504
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Refitting tables
8x8 up to 20F14
M 150 407 M 150 405 M 150 407 M 150 405 M 150 407 M 150 405 M 150 407 M 150 405
M 150 505
M 150 494 M 150 258 M 150 259 M 150 267 M 150 258 M 150 259 M 150 266 M 150 258 M 150 259 M 150 265 M 150 258 M 150 259
M 150 252 M 063 415 M 150 252 M 063 415 M 150 251 M 063 411 M 150 251 M 063 411
8x21 up to 32F14
M 150 505
8x33 up to 41F13
M 150 503
8x42 up to 56F13
M 150 503
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12.
12.1
2006-11-11
Barrel housing
Exploded views
Guide piston
Kit barrel housing
Guide sleeve
Flashshield support Linear motor
Guide flange
Pcb support
Pcb encoder
Measuring rule
Exploded views
47
12.2
2006-11-11
Gun handle left Pcb Interface LED Angle switch Type plate
Exploded views
Horizontal fastening (Option)
Kit Gun handle
Plastic cap
Welding strand Covering for corrugated tube Release lever Start button
48
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Operating Manual Stud welding Gun PLM 560

Please read the operating manual before any operation!

E-Mail: [email protected] Internet: www.tucker.de

Stud welding Gun PLM 560

Table of contents Table of contents:

Stud welding Gun PLM 560

Stud welding Gun PLM 560

Stud welding Gun PLM 560

General Information 1.3 Symbol legend

Tips and recommendations

Stud welding Gun PLM 560

Stud welding Gun PLM 560

General Information 1.5 Warranty

Stud welding Gun PLM 560

Responsibility of the operating company

Stud welding Gun PLM 560

Stud welding Gun PLM 560

Safety 2.3 Intended Use

Stud welding Gun PLM 560

Safety 2.4 Personal protective equipment

Protection clothes Wear flame resistant clothes protection of weld splatters.

Stud welding Gun PLM 560

Safety 2.5 Special risks

Stud welding Gun PLM 560

Technical Specifications 3. 3.1 Technical Specifications General Specifications

15 - 40 15 - 40 0 - 95 Indefinite < 75 < 2,5

Stud welding Gun PLM 560

Preface: Stud Welding 4. Preface: Stud Welding

Stud welding Gun PLM 560

General Description 5. General Description

Stud welding Gun PLM 560

Connection and Installation 6. Connection and Installation

Overview PLM 560

Stud welding Gun PLM 560

Connection and Installation 6.2 Connection cable package

Control and power unit

PLM 560 Control cabinet

Layout welding system

Control cable Weld cable Measurement line

Ground cable Ground-measurement line

Connection and Installation

Stud welding Gun PLM 560

Stud welding Gun PLM 560

Adjustments 7. 7.1 Weld Gun Adjustments Software Angularity switch

Stud welding Gun PLM 560

5. Select Process The green LED is flashing.

+ tol..:##### mm - tol..:##### mm.

Stud welding Gun PLM 560

Stud welding Gun PLM 560

Stud welding Gun PLM 560

Stud welding Gun PLM 560

Stud welding instructions 8.2 Stud welding process description

Welding current Weld stud distance

Light arc tension

Stud welding Gun PLM 560

Stud welding instructions 8.3 Notes on working with protective gas

Stud welding Gun PLM 560

Stud welding Gun PLM 560

Maintenance 10. 10.1 Maintenance Safety