A-A-59331-1999 STUD WELDING SYSTEMS INTEGRAL POWER SOURCE AND CONTROL UNIT MANUAL [Superseded DLA MIL-W-23680 E CANC NOTICE 1 DLA MIL-W-23680 E DLA MIL-W-23680 D DLA MIL-W-23680 C .pdf

1、c INCH-POUND A-A-5933 1 28 Seutember 1999 SUPERSEDING 18 October 1989 MIL- W-23 680E COMMERCIAL ITEM DESCRIPTION STUD WELDING SYSTEMS, INTEGRAL POWER SOURCE AND CONTROL UNIT, MANUAL The General Services Administration has authorized the use of this commercial item description for ail federal agencie

2、s. 1. SCOPE. This commercial item description (CID) covers electric arc and capacitor discharge stud welding systems with integral direct current power source, controller, and stud gun. The stud welding systems are intended for manual welding use in operations that require the rapid, reliable, and e

3、conomic attachment of stud fasteners or bolts to a plate or panel. 2. CLASSIFICATION. The stud welding systems shall be ofthe following types and sizes. The type and size to be furnished shall be as specified (see 7.2(b). Type I - Capacitor discharge (CD) Size 1 - 12 gauge through 1/4-inch Size 2 -

4、12 gauge through 5/16-inch Size 3 - U8-inch through 318-inch Type II - Electric arc Size 4 - 10 gauge through 1/2-inch Size 5 - 10 gauge through 5/8-inch Size 6 - 10 gauge through 3/4-inch Size 7 - 10 gauge through 7/8-inch Size 8 - 5/16-inch through 1-inch Size 9 - 10 gauge through 1-1/4-inch Benef

5、icial comments, recommendations, additions, deletions, clarifications, etc. and any other data which may improve this document should be sent to: Defense Supply Center Richmond (DSCR), ATTN: DSCR-VBD, 8000 Jefferson Davis Highway, Richmond, VA 23297-5610. AMSC N/A FSC 3431 DISTRIBUTION STATEMENT A.

6、Approved for public release; distribution is unlimited. Licensed by Information Handling ServicesA-A-5933 1 3. SALIENT CHARACTERISTICS 3.1 General recruirements. The system shall be new and one of the manufacturers current models capable of operation in accordance with the requirements herein. All p

7、arts subject to wear, breakage, or distortion shall be accessible for adjustments, replacement, and repair. 3.2 Comuonents. The stud welding shall include, as a minimum, the following components: 3.2.1 Power source and controller PSCl. 3.2.1.1 Twe I, stud welder. The PSC for type I stud welding syst

8、ems shall contain the capacitor bank and controls for power odoff, capacitance range, and charging voltage. The PSC shall possess jacks for the attachment of welding cables. The systems shall be initiai contact, drawn arc, or initial gap systems as specified (see 7.2(c). The PSC shall automatically

9、discharge after the power switch is placed in the “off position and shall have a protective device to prevent the capacitor voltage from being applied to the stud gun until the gun is properly seated on the workpiece. 3.2.1.2 TvDe II, stud welder. The II stud welding systems shall operate on the sta

10、ndard electric drawn arc principle. The PSC shall contain the transformer-rectifier and controls for power ordoff, welding current, and timing. The PSC shall possess connectors for the attachment of . welding cables. When specified (see 7.2(d), the systems shall be.capable of reverse polarity weldin

11、g. 3.2.2 Stud weldin? gun. The stud welding gun shali be constructed of nonconductive, high- impact material and shall be capable of withstanding the rigorous handling normally encountered in construction environments. The gun shall be of the pistol type with a finger-actuated switch that initiates

12、the welding process. 3.2.2.1 Stud welding gun adiustements. Type I and type II stud welding guns shall be equipped with adjustable support legs and stud chucks as specified (see 7.2(e) to accommodate desired stud lengths and diameters. Type II systems shall be equipped with stud gun feet and arc shi

13、eld ferrule grips as specified (see 7.2(f). 3.2.2.2 Dual-nun system. When specified (see 7.2(g), type II stud welders shall have a dual-gun system. 3.2.3 Welding cables. The stud welder shall possess a welding cable assembly to provide a means for conducting welding current and transmitting control

14、signals from the welding gun to the controller. A means shall be provided to securely clamp the ground lead(s) to the workpiece. Cable lengths shali be provided as specified (see 7.2(h). 3.2.4 Inert gas shielding eauipment. If required, the type II stud welding system shall be equipped with gas shie

15、lding accessories as specified (see 7.2(i). 2 Licensed by Information Handling Services9038054 0005578 343 811 A-A-5933 1 3.2.5 Portabilitv. Type I stud welding systems shall be manually portable. Type II systems shall be manually portable, or the base shall be equipped with wheels or with lifting e

16、ye(s) as specified (see 7.2G). 3.2.6 Electrical system. The electrical system shall conform to the American National Standards InstituteNational Fire Protection Association (ANSINFPA) 79, “Machinery, Industrial, Electrical Standard For“. Unless otherwise specified (see 7.2(k), type II stud welding s

17、ystems shall operate from a dual 230/460-v0lt, 3-phase, 60-hertz circuit and shall be wired for the voltage. Type I systems shall operate from a 120-volt, single-phase, 60-hertz circuit. Type II electrical systems shall provide current output regulation and thermal overload protection as specified (

18、see 7.2(1). 3.2.7 Outional accessories. Optional accessories shall be furnished as specified (see 7.2(m). 3.3 Performance. Unless otherwise specified (see 7.2(n), the stud welding system shall meet the performance requirements in sections 3.2.1 and 3.2.2 when tested in accordance with sections 5.3 t

19、hrough 5.3.3 herein. 3.3.1 Visual weld insuection. For the type I process, the fdlet formed at the base of the stud shall appear full and even. The weld shall not form a large crater with excessive metal expulsion or possess a very shiny appearance. For the type II process, the fillet shall appear f

20、ull, even, and shiny all around the stud. The fillet shall not possess a very shiny, low profde extending beyond the outside of the ferrule, nor shall it possess a small, uneven, or dull appearance with fmgers of metal extending through the vents of the ferrule. 3.3.2 Weld strength. A perpendicular

21、force with sufficient magnitude to bend the stud shal not cause failure or cracking in the weld. Failure can occur in the stud or the workpiece. 3.4 Machine dimensions and weight. If required, the maximum dimensions (length, width, and height) and machine weight shaii not exceed the restrictions spe

22、cified (7.2(0). 3.5 Safety and health requirements. The machine shall be designed and manufactured in accordance with ANSINational Electrical Manufacturers Association (ANSINEMA) EW i, “Welding, Electric Arc, Power Sources“, and ANSIAmerican Welding Society (ANSIAWS) C5.4, “Stud Welding, Recommended

23、 Practices For“. The manufacturer shall ensure that the stud welding system and all equipment and accessories supplied with the system shall be in compliance with ANSIAWS 249.1, “Safety In Welding And Cutting“, and Occupational Safety and Health Administration (OSHA) 29 CFR PART 1910, “Occupational

24、Safety and Health Standards for General Industry“. If a conflict arises between the ANSI and OSHA standards, the OSHA standards shall apply. Covers, guards, or other safety devices shall be provided for all parts of the system that present safety hazards. The manufacturer shall ensure that the syste

25、m is intended for manual use. A type II system having a power source with an open circuit voltage that is not in accordance with NEMA EW1 section 5.3.1 shall not be provided as a manual system. Should this situation occur, it shall be cause for rejection of the system. Licensed by Information Handli

26、ng ServicesII 9038054 0005579 2T W A-A-5933 1 3.6 Svstem of units. The U.S. Customary System of Units (US) or the International System of Units (SI) shall be used to graduate measuring and indicating devices. When only one system of graduation is acceptable, the particular graduation required shall

27、be as specified (see 7.2(p). Regardless of the measurement system used, all measuring and indicating devices on the mache shall be graduated in the same system. When specified (see 7.2(q), measuring and indicating devices shall be graduated in both the US and SI system of measurements. 3.7 Nameolate

28、. A nameplate shall be securely attached to the machine. Unless otherwise specified (see 7.2(r), the nameplate shall contain the following information: a. b. d. e. f. C. 1. Manufacturers name System model designation Power input (volts, total amperes, phase, frequency) Rated load volts and amperes M

29、aximum open circuit voltage Duty cycle at rated load Contract number or order number National stock number Date of manufacture 4. REGULATORY REQUIREMENTS 4.1 Recovered materials. The offerorkontractor is encouraged to use recovered materials to the maximum extent practicable, in accordance with para

30、graph 23.403 of the Federal Acquisition Regulation (FAR). 4.2 Environmental Drotection. The item shall meet all applicable Environmental Protection Agency restrictions in effect on the date of the contract. These regulations apply to the emission of materials hazardous to the environment or the user

31、s health and shall be adhered to during the manufacturing, service, transportation, storage, and operatioduse of the item. 5. QUALITY ASSURANCE PROVISIONS 5.1 Product conformance. The products shall meet the salient characteristics of this commercial item description; conform to the producers own dr

32、awings, specifications, standards, and quality assurance practices; and be the same system offered for sale in the commercial market. The government reserves the right to require proof of such conformance. 5.2 Inspection. The stud welding system shall be inspected to determine compliance with all re

33、quirements specified in this CID. 5.3 Testing. Unless otherwise specified (see 7.2(s), the stud welding system shall be tested in accordance with sections 5.3.1 through 5.3.3. 4 Licensed by Information Handling ServicesA-A-5933 1 5.3.1 Test conditions. The stud welding system shall be tested in an i

34、ndoor facility under the ambient temperature and humidity conditions that normaiiy occur within the facility. 5.3.2 Operational test. The stud welding system shall be operated in accordance with the manufacturers standard operating procedures. The system shall be operated at no load for not less tha

35、n 30 minutes. Proper operation of all controls and features shall be verified during the trial period. 5.3.3 Performance tests. The performance tests shall consist of welding 10 round studs of the smallest diameter for the size machine under test. The procedure shaii be repeated for 10 studs of the

36、maximum diameter for the size machine under test. The workpieces for the tests shall be flat plates with a minimum thickness 1/3 the diameter of the test studs. The workpieces and studs shall consist of C- 1008 to C- 1022 steel. The welded studs shall be inspected visually to determine compliance wi

37、th the requirements of section 3.3.1. Each welded stud shall undergo a bend test whereby a hammer or pipe is used to bend the stud to a minimum of 45 degrees from vertical. The welded studs shall comply with the requirements of section 3.3.2. 5.4 Acceptance. Unless otherwise specified (see 7.2(t), p

38、reliminary and final acceptance tests shall be conducted at the manufacturers site. The results of the performance tests shall be compared to the performance requirements of sections 3.3.1 and 3.3.2. Failure ofthe system to meet the performance requirements shall be cause for rejection. 6. PACKAGING

39、 6.1 Preservation. packing. and marking. For acquisition purposes, the products shall be preserved, packed, and marked as specified in the acquisition order (see 7.2(u). 7. NOTES 7.1 Sources of documents. 7.1.1 &R. The FAR may be obtained from the Superintendent of Documents, U.S. Government Printin

40、g Ofice, Washington, DC 20402-0001. 7.1.2 ANSI standards. Copies of ANSI standards may be obtained fiom the American National Standards Institute, 11 West 42nd Street, New York, NY 10036. 7.1.3 NFPA standards. Copies of NFPA standards may be obtained from the National Fire Protection Association, 1

41、Batterymarch Park, Quincy, MA 02269-9101. 7.1.4 NEMA standards. Copies of NEMA standards may be obtained from the National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1847, Rosslyn, VA 22209 7.1.5 OSHA standards. Copies of OSHA standards may be obtained from the U.S. Departme

42、nt of Labor, 200 Constitution Avenue NW, Room 423, Washington, DC 20210. 5 Licensed by Information Handling Servicesq038054 O005583 938 0 A-A-5933 1 7.2 Ordering data. Acquisition documents must specifl the followhg information: a. b. d. e. f. g. h. C. 1. i k. 1. m. n. P. 9. r. t. U. O. S. Title, nu

43、mber, and date of this document Type and size of stud welding system required (see 2) Specifl initial contact, drawn arc, or initial gap, as required (see 3.2.1.1) Reverse polarity capability, if required (see 3.2.1.2) Stud gun legs and chucks, as specified (see 3.2.2.1) Stud gun foot and ferrule gr

44、ip, as specified (see 3.2.2.1) Dual-gun system, if required (see 3.2.2.2) SpeciQ cable length (see 3.2.3) Gas shielding accessories, if required (see 3.2.4) Wheels or Ming eye(s), as specified (see 3.2.5) Electrical requirements, if different (see 3.2.6) Type II line regulation, current output regul

45、ation, thermal overload protection, as specified (see 3.2.6) Optional equipment, as specified (see 3.2.7) Performance, if different (see 3.3) Mache dimensions and weight, if required (see 3.4) System of units required (see 3.6) Dual system of units, if required (see 3.6) Nameplate, if different (see

46、 3.7) Testing, if different (see 5.3) Acceptance, if different (see 5.4) . Packaging requirements (see 6) 7.2 Part identification number (PIN). The.fol1owing part identification numbering system is for government purposes and does not constitute a requirement for the contractor. - 331 - gX Size 1 -

47、12 gauge through 1/4-inch Size 2 - 12 gauge through 5/16-inch Size 3 - 1/8-inch through 3/8-inch Size 4 - 10 gauge through 1/2-inch Size 5 - 10 gauge through 5/8-inch Size 6 - 10 gauge through 3/4-inch Size 7 - 10 gauge through 7/8-inch Size 8 - 5/16-inch through 1-inch Size 9 - 1 O gauge through 1

48、- 1 /4-inch I Type: A - Type I, Capacitor discharge (CD) B - Type II, Electric arc u CIDnumber 6 Licensed by Information Handling ServicesMILITARY INTERESTS: Custodians: Air Force - 99 Army - AL Navy - SH Reviewers: Air Force - 84 Navy - AS, CG Army - AV, CE 1111 9028054 0005582 874 A-A-59331 CIVIL AGENCY COORDINATING ACTIVITY: GSA - 6FET Preparing activity: DLA - GS (Project 343 1-0252) 7 Licensed by Information Handling Services