Hilti FX 3-A Stud Fusion Machine Manuel utilisateur

FX 3-A

English 1

Français 20

Español 40

Português 60

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

FX 3-A

en Originaloperatinginstructions....................................... 1

fr Moded'emploioriginal ........................................... 20

es Manualdeinstruccionesoriginal .................................... 40

pt Manualdeinstruçõesoriginal ...................................... 60

*2302409* 2302409 English 1

Original operating instructions

1 Information about the operating instructions

1.1 About these operating instructions

• Read these operating instructions before the product is used or operated for the first time. This is a

prerequisite for safe, trouble-free handling and use of the product.

• Observe the safety instructions and warnings in these operating instructions and on the product.

• Always keep the operating instructions with the product and make sure that the product is accompanied

by these operating instructions only, when the product is given to other persons.

1.2 Explanation of symbols

1.2.1 Warnings

Warnings alert persons to hazards that occur when handling or using the product. The following signal words

are used:

DANGER

DANGER !

▶Draws attention to imminent danger that will lead to serious personal injury or fatality.

WARNING

WARNING !

▶Draws attention to a potential threat of danger that can lead to serious injury or fatality.

CAUTION

CAUTION !

▶Draws attention to a potentially dangerous situation that could lead to personal injury or damage to the

equipment or other property.

1.2.2 Symbols in the operating instructions

The following symbols are used in these operating instructions:

Comply with the operating instructions

Instructions for use and other useful information

Dealing with recyclable materials

Do not dispose of electric equipment and batteries as household waste

Hilti Liion battery

Hilti charger

1.2.3 Symbols in illustrations

The following symbols are used in illustrations:

These numbers refer to the illustrations at the beginning of these operating instructions.

The numbering reflects the sequence of operations shown in the illustrations and may deviate

from the steps described in the text.

Item reference numbers are used in the overview illustration and refer to the numbers used in

the key in the product overview section.

This symbol is intended to draw your special attention to certain points for handling the product.

2 English 2302409 *2302409*

1.3 Product-dependent symbols

1.3.1 General symbols

Symbols used in relation to the product.

The power tool supports near-field communication (NFC) technology, which is compatible with

iOS and Android platforms.

Direct current (DC)

General warning symbol

If applied on the product, the product has been certified by this certification body for the US and

Canadian markets according to the applicable standards.

1.3.2 Obligation symbols

Mandatory actions

Read the operating instructions

Wear protective gloves

Wear hearing protection

Wear eye protection

1.3.3 Warning signs

Hazard warning

Warning: Non-ionizing radiation

Warning: Magnetic field

Warning: Electric voltage

Warning: Flammable substances

Warning: hot surface

1.4 Product information

Hilti products are designed for professional use and may be operated, serviced and maintained only by

trained, authorized personnel. This personnel must be specifically informed about the possible hazards. The

product and its ancillary equipment can present hazards if used incorrectly by untrained personnel or if used

not in accordance with the intended use.

The type designation and serial number are printed on the rating plate.

▶Write down the serial number in the table below. You will be required to state the product details when

contacting Hilti Service or your local Hilti organization to inquire about the product.

Product information

Stud welding machine FX 3-A

Generation 01

Serial no.

*2302409* 2302409 English 3

2 Safety

2.1 Safety instructions

WARNING Study all safety instructions and other instructions, images and technical data with

which this power tool is provided. Failure to observe the instructions below can result in electric shock,

fire and/or serious injury.

Keep all safety instructions and instructions for future reference.

Read all operating instructions and other documents about all the system components used.

Work area safety

▶Make sure that the work area is well ventilated.

▶Keep your work area clean and well lit. Cluttered or dark work areas invite accidents.

▶Keep the work area and the surrounding air free from dust and other substances such as corrosive gases.

▶Set the product on a smooth, horizontal surface or implement suitable measures to prevent the product

from tipping over.

▶Keep children and other persons clear when the product is in use.

Electrical safety

▶An electric shock can be life-threatening or even fatal. Do not touch live parts inside or outside the

product.

▶Check that all connectors and connections are secure and replace damaged leads before use. All

leads and lines must be securely connected, undamaged and insulated.

▶Disconnect the connection between product and charger and switch the product off before carrying out

cleaning and maintenance work.

▶Avoid body contact with earthed or grounded surfaces such as pipes, radiators, cookers, stoves and

refrigerators.

Personal safety

▶Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use

a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of

inattention while operating the power tool may result in serious personal injury.

▶Wear personal protective equipment consisting of protective clothing covering the entire body,

protective gloves, safety footwear, hearing protection and protective eyewear with side shields

providing protection against UV radiation, heat and flying sparks.

▶When the product is in use, the arc radiation can be harmful to the eyes and to the skin. Wear

personal protective equipment. Do not look directly into the welding arc. Comply with national, local and

jobsite-specific health and safety requirements.

▶On account of the welding current there is a risk of electric shock. Keep the distance between the

stud to be welded and the ground connection as short as possible and check that the ground clamp has

a secure connection to the workpiece.

▶When the product is in use welding fumes and other gases harmful to health are produced. To

reduce the production of gases harmful to health, in all steps of the procedure follow the directions in

these operating instructions. Make sure that the work area is well ventilated. Comply with national, local

and jobsite-specific health and safety requirements.

▶Do not weld on surfaces that are contaminated with oil or other flammable materials. Vapors such

as solvent vapors are flammable and can cause burns.

▶The front, metallic part of the hand tool becomes hot in use and can cause burns. Do not touch this

area before the hand tool has cooled down completely.

Using and handling the product

▶Do not expose the product to rain or moisture. Penetrating moisture can cause short circuits, electrical

shock, burns or explosions.

▶Flying sparks can start fires and cause explosions. Sparks and hot pieces of metal can also pass

through small cracks and openings and make their way into other areas. Never use the product in the

immediate vicinity of flammable materials. If this is not possible, use a suitable cover. Comply with

national, local and jobsite-specific health and safety requirements.

▶Do not use the welding machine where there is a risk of fire or explosion, on closed tanks, drums

and pipes. Before welding the materials stated above, prepare them in accordance with the national and

international standards. Comply with national, local and jobsite-specific health and safety requirements.

▶Inert-gas cans contain pressurized gas and can explode if damaged. Protect inert-gas cans

from excessive heat, mechanical damage, scale, naked flame, sparks and electric arcs. Follow

the manufacturer's specifications and national and international regulations for inert-gas cans and

accessories. Dispose of inert-gas cans only when they are completely empty.

4 English 2302409 *2302409*

▶Use the product and accessories only when they are in perfect working order.

▶Never tamper with or modify the product or accessories in any way.

▶Check that moving parts operate satisfactorily and do not jam, and make sure that no parts are broken

or damaged in such a way that the product might no longer function correctly.

▶Before you switch the product on, make sure that no-one is going to be put at risk.

▶To allow sufficient cooling air to enter and exit, when setting up the equipment make sure that it has

50 cm (20 in) of clear space all round.

▶Never use the welding machine on pressurized gas containers.

▶An inert-gas can that is not correctly connected or that is damaged is a potential hazard. Check the

connection of the inert-gas can before use and dispose of damaged inert-gas cans in accordance with

your local regulations.

▶Do not charge or continue to use a damaged welding machine (for example cracks, broken parts,

contacts bent, pushed in or pulled out).

▶Do not use damaged accessories or studs.

▶Switch the product off before changing accessories or setting the product aside.

Electric and Magnetic Fields (EMF)

Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding

current creates EMF fields around welding cables and welding machines. EMF may interfere with pacemakers,

hearing aids and other sensitive medical devices. Users and persons working in the near vicinity of the

welding machine, cables and user should consult their physician before working with or in the near vicinity of

this welding machine. Exposure to EMF in welding may have other health effects which are now not known.

The user and all persons in the near vicinity should do the following to minimize exposure to EMF fields

during welding:

• Bundle the lines of the hand tool and the ground cable and secure all lines with adhesive tape.

• Do not place your body between the electrode and the ground cable. If the electrode is on your right

side, the ground cable should also be on your right side.

• Never sling, wrap, or coil the lines around your torso or any body part.

• Keep lines away from head and torso.

• Connect the ground cable to the workpiece as described in these instructions.

• Do not work in the immediate vicinity of the welding machine.

EMF emissions may interfere with surrounding sensitive equipment, including but not limited to:

• Network, signal and data-transmission lines

• Data-processing and telecommunications equipment

• Measurement and calibration equipment

It is the operator's and user's obligation to implement appropriate measures to check, assess, and if

necessary, rectify interferences with equipment in the vicinity of the welding machine and application point(s)

in accordance with international, national, local, or jobsite regulations.

Service

▶Have your product repaired only by Hilti Service and only with genuine Hilti spare parts. The safety of

the product can thus be maintained.

▶Stud welding might require additional quality measures according to international and local regulation.

Hilti will provide guidance on Welding Procedure Specification, Welding Procedure Qualification Record

and on Factory Process Control in accordance with international regulation. If you require further support,

consult Hilti Service.

2.2 Careful handling and use of cordless welding machines

▶Comply with the following safety instructions for the safe handling and use of products with Li-ion

batteries. Failure to comply can lead to skin irritation, severe corrosive injury, chemical burns, fire and/or

explosion.

▶Use only the Hilti C 53 charger to charge the welding machine. There is a risk of fire if any other charger

is used.

▶Follow the charging instructions in these operating instructions and in the operating instructions of the

charger. Do not charge the product outside the stated temperature range. Incorrect charging or charging

at temperatures outside the defined range can damage the battery or increase the risk of fire.

▶Make sure that the product is switched off when it is not in use. Keep the product well away from other

metallic objects such as paper-clips, coins, keys, nails and other small metallic objects that could create

a conductive bridge from one connection to the other. Short-circuiting connections can cause burns or

fires.

*2302409* 2302409 English 5

▶Misuse can result in battery fluid escaping from the product. Avoid contact with this liquid. If contact

accidentally occurs, rinse with water. Seek medical attention if the liquid comes into contact with the

eyes. Liquid escaping from the battery can cause skin irritation or burns.

▶Treat the product with care in order to avoid damage and prevent leakage of fluids that are extremely

harmful to health!

▶Do not use a damaged or modified welding machine. Damaged or modified components and products

can exhibit unpredictable behavior that can lead to explosions or risk of injury.

▶Do not disassemble, squash or incinerate the product and the installed battery, do not subject them to

temperatures above 80 °C (176 °F) or burn them. Fire or temperatures above 130 °C (265 °F) can lead to

an explosion.

▶Never expose the product to the direct rays of the sun, elevated temperature, sparking, or open flame.

This can lead to explosions.

▶If the product is too hot to touch, it may be defective. Put the product in a place where it is clearly visible

and where there is no risk of fire, at an adequate distance from flammable materials. Allow the product

to cool down. If the product is still too hot to touch after an hour, it is faulty. Consult Hilti Service or read

the document entitled "Instructions on safety and use for Hilti Li-ion batteries".

Observe the special guidelines applicable to the transport, storage and use of lithium-ion batteries.

→ page 15

Read the instructions on safety and use of Hilti Li-ion batteries that you can access by scanning

the QR code at the end of these operating instructions.

3 Description

3.1 Product overview, welding machine 1

@Current socket (-) for current connector of

the hand tool

;Control-line connection

=Current socket (+) for ground lead

%Cover, inert-gas can

&Eye for attaching the shoulder strap

(Charger connection

)Air-filter flap

+Blanking cover (no function)

§Grip

/Connection for inert-gas can

:Operating status indicator

∙Process-fault indicator

$Display

£On/off button

|Adjuster button, right

¡Adjuster button, left

QTemperature-fault indicator

WHand-tool fault indicator

EGas-level indicator

RBattery state of charge indicator

TService indicator

6 English 2302409 *2302409*

3.2 Product overview, hand tool 2

@Stud holder

;Shielding ring

=Belt hook

%Trigger

&Support leg

(Eye for attaching the tool tether

)Control connector

+Current connector (-)

§AFI (Active Fusion Indicator)

/Fault indicator

:OK button

3.3 Overview, system components 3

@C 53 charger

;Welding machine FX 3A

=Inert-gas can FX 3GC

%FX 3HT hand tool, with lines

&Ground lead

(Cable clamp

)Magnetic foot

+Cordless drill / driver Hilti SF 6A22

§Surfacing tool

/Setting tool for sealing washer

3.4 Intended use

The product described is a cordless stud welding machine. It is designed for welding FBT studs to steel on

the principle of drawn-arc welding.

• Use only Hilti chargers of the C 53 series. More information is available from your Hilti Store or from

www.hilti.group

• Observe the operating instructions and other documents for the studs, the inert-gas can and all other

system components used.

3.5 Cordless Stud Fusion technology

The Cordless Stud Fusion (CSF) technology is based on the principle of stud welding by drawn arc.

This welding process consists of several phases. The sequencing of the individual welding phases is fully

automated and requires no additional control intervention by the user.

The five phases of the welding operation:

1. In the first phase, the inert-gas atmosphere is created. Inert gas flows to the front part of the hand tool,

where it displaces the atmospheric air.

2. Current flows through the stud to the base metal, while at the same time the stud is lifted in a controlled

movement until there is a gap of defined size between it and the base metal. This produces a stable pilot

arc, initially of low power. In this phase there is no appreciable melting of stud or base metal.

3. The power of the arc is surged to maximum, with current flux now automatically increased to the target

value. The power of the arc is now sufficient to melt the tip of the stud and the base metal.

4. Welding is completed by the system. The stud is moved toward the base metal. Molten material from

base metal and stud mix.

5. The stud is briefly held in this position and the molten metal hardens. More inert gas flows round the

weld, protecting against oxidation.

3.6 AFI (Active Fusion Indicator)

The welding machine assists the user in carrying out the welding process correctly, increasing the achievable

quality of the weld. The achievable quality of a weld depends on many influencing factors.

*2302409* 2302409 English 7

Certain process deviations from the expected sequence can be detected and brought to the attention of the

user. No assessment of weld quality is made by this process analysis. It is not possible to detect all faults.

This process analysis is not a substitute for diligence and quality control on the part of the user!

If an irregularity is detected, always check the fault indicator on the welding machine and consult the

Troubleshooting → page 15 section.

Indicator System

ready for

use

Hand tool

with stud

inserted

pressed

against

base metal,

ready for

triggering

During the

welding

operation

Welding

operation

completed,

no irregu-

larities

Welding

operation

completed,

irregular-

ities de-

tected

Hand tool AFI Green

light

Green

light

Green

light

Off Off

Fault indi-

cator

Off Green

light

Green

light

Off Flashing

red light

Welding

machine

Operating

status indica-

tor

Green

light

Green

light

Green

light

Green

light

Off

Service

indicator

Off Off Off Off Off

Process-

fault indicator

Off Off Off Off Flashing

red light

Hand-tool

fault indicator

Off Off Off Off Off

Tempera-

ture indicator

Off Off Off Off Off

3.7 Battery protection function

The product has a battery protection function to protect the battery against deep discharge. The battery

protection function warns the user when battery charge state is too low and switches the product off after 3

minutes.

Indicators

Indicator Meaning

Battery is discharged

‘F.02’ Battery discharged - the deep discharge prevention system has tripped.

3.8 Automatic power-off

The product has an automatic shutdown to extend the battery's operating time. The product shuts down

automatically if 60 minutes pass without a welding operation taking place.

3.9 Indicators for gas fill level and battery,

Indicator Meaning Indicator Meaning

Inert-gas can full Battery fully charged

Inert-gas can 75 % full Battery 75 % full

Inert-gas can 50 % full Battery 50 % full

Inert-gas can 25 % full Battery 25 % full

8 English 2302409 *2302409*

Indicator Meaning Indicator Meaning

Fault indicator

shows simulta-

neously ‘F.05’

Inert-gas can empty

Fault indicator

shows simulta-

neously ‘F.02’

Battery is discharged

3.10 Items supplied

Cordless welding machine, operating instructions

Other system products approved for use with this product can be found at your local Hilti Store or at:

www.hilti.group

4 Technical data

4.1 Welding machine

Battery nominal voltage 52.8 V

No-load voltage 58 V

Charging current 10 A

Charging current, fast charge 18 A

Battery capacity 7.5 Ah ⁄ 396 Wh

Battery type Liion

Typical charging time on fast charge (to 80 % battery

capacity)

30 min

Typical charging time (to 80 % battery capacity) 50 min

Typical range with full battery charge, depending on stud

size

250 ... 1200 welding operations

EMC classification Emissions class A

Dangerous goods class 9

Classification code M4

Packaging group II

Cooling AF

Degree of protection IP 23

Dimensions (L x W x H) 434 mm x 160 mm x 393 mm

(17.1 in x 6.3 in x 15.5 in)

Weight 12 kg

(26 lb)

Maximum relative humidity during oper-

ation

20 °C (68 °F) 90 %

40 °C (104 °F) 50 %

Ambient temperature for operation −20 ℃ … 40 ℃

(−4 ℉ … 104 ℉)

Temperature of welding machine / hand tool during oper-

ation

5 ℃ … 40 ℃

(41 ℉ … 104 ℉)

Temperature of workpiece / stud 0 ℃ … 40 ℃

(32 ℉ … 104 ℉)

Storage temperature −20 ℃ … 50 ℃

(−4 ℉ … 122 ℉)

Temperature of welding machine at start of charging 4 ℃ … 40 ℃

(39 ℉ … 104 ℉)

*2302409* 2302409 English 9

Maximum pressure of the inert gas 168 bar

(2,440 psi)

Storage temperature, inert-gas can −20 ℃ … 50 ℃

(−4 ℉ … 122 ℉)

5 Preparations at the workplace

▶Check all components for damage and replace damaged components.

▶Before use, make sure that the ground clamp and the stud holder are free of contaminants.

5.1 Setting up the product

Set-up conditions for charging and in operation

• Do not cover up the product. Air must be able to flow unhindered through the air vents at front and rear.

• To prevent product damage due to insufficient air supply, make sure that there is a clear space of 0.5 m

(2 ft) all round the product.

• Make sure that the fan does not induct metallic dust (e.g. from grinding work).

• The surface on which the product is set must be smooth and level, so that the product does not tip over

or fall.

5.2 Charging cordless welding machine

Fully charge the product before using it for the first time.

Over a long period of non-use, charge the product regularly every 6 months to prevent deep discharge.

▶Charge the product as described in the operating instructions of the Hilti C 53 charger.

You can resume operation of the product when the battery has charged to ≥25 % capacity.

5.3 Changing inert-gas can 4

CAUTION

Risk of injury by gas escaping during gas can replacement. Hearing damage.

▶Wear hearing protection.

CAUTION

Risk of damage to the seal due to flash-chilling. Escaping inert gas has the effect of flash-chilling the seal

on the gas can connection. The chilled seal can be damaged and consequently leak.

▶Unscrew the used gas can from the connection slowly.

▶Wait at least 2 minutes before inserting a new gas can.

Change the inert-gas can when it is empty. See the section headed Indicators for gas fill level and battery

→ page 7.

Comply with the safety data sheet of the inert-gas can.

1. Open the cover.

2. Fully unscrew the inert-gas can counter-clockwise from the connection.

▶In this process, residual gas escapes from the inert-gas can with a loud hiss.

3. Screw the new inert-gas can clockwise into the connection and tighten the can hand-tight.

Materials

Inert-gas can FX 3GC

10 English 2302409 *2302409*

4. Close the cover.

▶The action of closing the cover pierces the inert-gas can.

5.4 Installing / changing stud holder 5

WARNING

Risk of injury by stud holder! The stud holder gets hot in use.

▶To avoid burns, wait until the stud holder has cooled down.

▶Wear protective gloves when changing the stud holder.

1. Make sure that the welding machine is switched off. → page 12

2. Twist the shielding ring counter-clockwise by hand and remove it from the hand tool.

3. If a stud holder is installed, use the following tools to unscrew the stud holder counter-clockwise to

remove it from the hand tool:

Materials

SBT 1⁄4" torque screwdriver - 5 Nm

XSHT F3 accessory tool for stud change

▶To avoid damage, insert the accessory tool fully into the stud holder.

▶To avoid damage, do not use any tool other than the recommended torque screwdriver.

Replace the shielding ring and/or stud holder if worn. → page 14

4. Screw the stud holder you need into the hand tool, tightening the stud holder clockwise to the specified

tightening torque. When the required tightening torque is reached the torque screwdriver disengages

with haptic and acoustic feedback.

Technical data

Tightening torque for stud holder 5 Nm

(4 ftlbf)

Materials

SBT 1⁄4" torque screwdriver - 5 Nm

For more information on the stud holders, consult the operating instructions that accompany the

studs.

5. Set the shielding ring on the bayonet connector on the hand tool and twist it clockwise until it engages.

5.5 Connecting hand tool and ground lead 6

CAUTION

Risk of damage due to incorrect connecting sequence.

▶To prevent damage, make the connections in the correct sequence.

1. Make sure that the welding machine is switched off.

2. Connect the current connector of the hand tool to the minus current socket and latch it in position by

turning it clockwise.

3. Connect the control connector of the hand tool to the welding machine and latch it in position by turning

it clockwise.

4. Connect the connector of the ground cable to the plus current socket and latch it in position by turning it

clockwise.

La page est en cours de chargement...

Hilti FX 3-A Stud Fusion Machine Manuel utilisateur

Hilti FX 3-A Stud Fusion Machine Manuel utilisateur

dans d''autres langues