IT 3002 Operating Manual

IT 3002

Power Unit

93-66-3211

Operating Manual

Customer Service in Germany:

HBS Bolzenschweiss-Systeme GmbH & Co. KG

Felix-Wankel-Strasse 18

85221 Dachau / Germany

Phone +49 (0) 8131 511-0

Fax +49 (0) 8131 511-100

E-mail [email protected]

Web www.hbs-info.com

ii

IT 3002 Operating Manual, Issue 06/2008 Order No. BA 93-66-3211

Copyright:

The information contained herein may not be copied, reproduced, adapted, merged, translated or used without the prior written consent of the copyright owner.

Adaptations, errors and technical modifications reserved without prior notice.

©

HBS Bolzenschweiss-Systeme GmbH & Co. KG

ii

IT 3002 Order No. BA 93-66-3211 Issue 20.06.08

Dear customer,

Thank you very much for purchasing a power unit from HBS Bolzenschweiss-

Systeme.

We from HBS wish you always successful working with this stud welding unit.

We ask you to observe the following points:

– Store the operating manual in a way that it can always be accessed by the operator.

– Let the operator sign before starting up that he has read and completely understood the operating manual.

– This operating manual applies only to this stud welding unit.

– Protect the stud welding unit from unauthorized use.

– The stud welding unit must only be operated by trained personnel.

– Let an electrician check whether the wall sockets where you want to connect the related stud welding unit, are properly fused and grounded.

– Inform our customer service in case of malfunction.

– In case of accident, inform a physician and the responsible official body.

THREAT TO LIFE!

Persons fitted with a pace maker must not operate the stud

welding machine.

MAGNETIC FIELDS!

During stud welding, strong electro-magnetic fields are generated. Do not weld in the vicinity of the electrical equipment which could be affected.

Safety instructions are a delicate subject. Anybody who handles a stud welding unit, whether it is the welding gun or the power unit, should be familiar with them, because improper use of stud welding units can be dangerous to life.

For your own sake you should know the safety instructions for operating your HBS stud welding units inside out.

In addition to the protection of your health and the capital value of the enterprise, the safety instructions are intended to clarify any responsibilities, which arise from ownership and operation of the equipment.

This chapter of the operating manual offers you clear and easy to understand information for the safe operation of your HBS stud welding unit.


iii iii

Your power unit may differ in some details from the captions in this manual. This has no effect on the operation of the welding machine.

Should you have questions about this manual or in case you want to order some more copies, please provide the order number listed in the foot line.

Important reminder:

Data and information herein were collected with greatest care. Although we did our very best to correctly update any information up to the time of delivery, there is no guarantee in respect of errors.

If you should detect errors or mistakes right in this manual, please contact us:


Felix-Wankel-Strasse 18

85221 Dachau / Germany

A feedback blank is provided in the appendix.

iv iv


Table of Contents


2

3

3.1

3.2

3.3

3.4

3.5

4

4.1

4.1.1

4.1.2

4.2

5

5.1

5.2

5.2.1

5.2.2

5.2.3

5.2.4

5.3

5.4

5.5

1

1.1

1.2

1.3

1.4

1.5

1.6

1.7

General ............................................................................................. 9

Guide to this Operating Manual .................................................................. 10

Safety Symbols .......................................................................................... 11

General Safety Instructions ........................................................................ 12

Intended Use .............................................................................................. 12

Transportation, Packaging, Storage ........................................................... 13

Accompanying Documents ........................................................................ 13

Markings ..................................................................................................... 14

Delivery ........................................................................................... 15

Starting-up ..................................................................................... 16

Requirements of Workplace ...................................................................... 16

Connecting the Power Unit to the Primary Power Supply .......................... 17

Connecting the Welding Gun to the Power Unit ......................................... 18

Ground Connection .................................................................................... 19

Change Working Place .............................................................................. 19

Function ......................................................................................... 20

Components of the Power Unit .................................................................. 20

Power Unit ............................................................................................................. 20

Control Unit ............................................................................................................ 21

Keyboard and Display ................................................................................ 21

Stud Welding Procedure ............................................................... 22

Safety Instructions ...................................................................................... 22

Functional Principle of Stud Welding .......................................................... 25

Drawn-Arc Stud Welding with Ceramic Ferrule ....................................................... 27

Drawn-Arc Stud Welding with Shielding Gas .......................................................... 28

Short-Cycle Drawn-Arc Stud Welding with Shielding Gas ....................................... 29

Drawn-Arc Capacitor-Discharge Stud Welding ........................................................ 29

Welding Preparation ................................................................................... 30

High-strength Welds ................................................................................... 30

Determination of Welding Parameters ....................................................... 30


v


7

7.1

7.2

7.3

7.4

5.8

5.8.1

5.8.2

5.8.3

5.9

5.10

5.6

5.6.1

5.6.2

5.6.3

5.6.4

5.7

6

6.1

6.2

8

8.1

8.2

8.3

8.4

Switching on the Power Unit ...................................................................... 32

Adjusting the Welding Time ................................................................................... 33

Adjusting the Welding Current ................................................................................ 33

Library Mode .......................................................................................................... 34

Conversion Current Curve ....................................................................................... 34

Welding Procedure .................................................................................... 35

Checking the Quality of the Weld ............................................................... 36

Visual Inspection ................................................................................................... 36

Bending Test .......................................................................................................... 37

Arc Blow Effect ...................................................................................................... 39

Malfunctions and Corrective Actions .......................................................... 40

Welding Elements ...................................................................................... 41

Switching off the Power Unit ........................................................ 44

Temporary Switching off ............................................................................. 44

Disposal ..................................................................................................... 44

Care and Maintenance .................................................................. 45

Safety Instructions ...................................................................................... 45

Regular Maintenance Operations ............................................................... 45

Tools to be Used ......................................................................................... 45

Open the Power Unit .................................................................................. 46

Appendix ........................................................................................ 47

Technical Data ............................................................................................ 47

Spare Parts ................................................................................................ 48

Circuit Diagram .......................................................................................... 60

Environmentally Admissible Disposal ......................................................... 61

vi IT 3002 Order No. BA 93-66-3211 Issue 20.06.08


Glossary ......................................................................................... 62

Regulations and Standards .......................................................... 63

Further Instructions ....................................................................... 65

Guarantee Clauses ........................................................................ 66

Confirmation .................................................................................. 67

Feedback ........................................................................................ 68

Service & Support ......................................................................... 69

Index ............................................................................................... 70


vii


viii IT 3002 Order No. BA 93-66-3211 Issue 20.06.08

1 General

1 General

Persons addressed by this operating manual

This operating manual is written for operators, personnel of the end user, and authorized service technicians. It provides you with all necessary information to operate the power unit.

Required user qualification

The power unit must only be operated by qualified personnel.

Let the power unit only be operated by persons who

– are qualified through a suitable training according to the current standards (see appendix),

– are properly instructed,

– are physically and intellectually suitable,

– can be expected to reliably fulfill the requested job.

What else must the owner observe?

Make sure that this operating manual is always in reach of the stud welding unit.

Read the entire manual before operating the power unit.

Strictly observe the safety instructions.

Before starting up the power unit, let the operator sign the confirmation that he/ she has read and fully understood the operating manual (see appendix).

Do not commence stud welding until you have understood all operating processes.

Contact us if there are any doubts on certain operating procedures.

Protect the power unit against unauthorized use.

Inform our service in case of malfunction.

Based on this operating manual, a company specific work order, as well as a company specific maintenance instruction must be drawn up. The company specific work order must consider the special user conditions in your company.

Make sure that operators of the welder are provided with and wear personal protective equipment, e.g. protective goggles, gloves, shoes, ear protection etc.

Owners and operators make sure that the power unit is only used as directed.

During any activity such as transportation, set-up, (re-)assembly, production, maintenance etc. observe the information given in this operating manual.


9

1 General

1.1 Guide to this Operating Manual

1.1

Guide to this Operating Manual

This operating manual provides you with the following information

"Delivery" in Chapter 2

"Starting-up" in Chapter 3

"Functional Principle"

"Stud Welding Process"

"Switching off the Power Unit"

"Care and Maintenance"

Technical Data and much more in Chapter 4 in Chapter 5 in Chapter 6 in Chapter 7 in Appendix

THREAT TO LIFE and risk of serious health and material damage in case of improper use of the power unit. Observe all notes in this operating manual.

Note for qualified operators (see chapter 1).

All instructions contained in this manual must also be observed by qualified operators.

The welding process and the sequence of procedures to carry out a weld are described in chapter 5.

10 IT 3002 Order No. BA 93-66-3211 Issue 20.06.08

1.2

Safety Symbols

Symbols and markings used in this operating manual mean:

Threat to life or risk of personal injury

–

Risk of material damage

Ban for persons fitted with a pace maker

Warning of dangerous electrical voltage

Warning of electromagnetic fields

Wear protective clothes

Wear protective goggles

Wear ear protection

Additional tips for operation and service safety

Prompt

List

1 General

1.2 Safety Symbols


11

1 General

1.3 General Safety Instructions

1.3

1.4

General Safety Instructions

Improper operation of the power unit is LIFE-THREATENING!

Threat to life

– by electric shock and arc

– by toxic vapors and airborne particles

– by red-hot metal spatters (fire risk)

– by blow-up of explosive gases and materials

– by strong magnetic fields for persons fitted with a pace maker

In addition, through improper use damage to the stud welding unit and to material can be caused. For details, see chapters 1, 3 and 5.

Intended Use

Warning: Unauthorized interference with the stud welding unit as well as unauthorized alteration of the stud welding unit are prohibited and result in complete cancellation of any guarantee and liability claims against HBS.

Operation of the power unit is only allowed with HBS welding guns, this clause is also part of ”use as directed”.

The power unit is intended to weld welding elements according to actual standards (see chapter 5 and appendix). Any other use is regarded as not used as directed. The manufacturer is not liable for damages resulting from the stud welding unit not used as directed. Any risk is carried by the user.

The power unit is designed according to specific standards and accident prevention regulations. Basics are European Union guidelines and in Germany valid standards.

Please note that in your country additional standards and safety conditions (especially rules for accident prevention) may differ from the standards mentioned in this operating

manual. The power unit was manufactured to the latest developments in technology and is regarded as safe to operate (place of operation see section 8.1).

The welding guns A 16, A 22 and A 25 can be connected to the HBS power unit IT 3002. For details please contact the HBS customer service (address see page ii).

Check in any case the operating manual of the HBS welding gun whether this power unit can be used.

Observing the operating manual of the used welding gun is also part of the ”use as directed”.


1 General

1.5 Transportation, Packaging, Storage

1.5

Transportation, Packaging, Storage

HBS delivers products in a specific transport package.

Save the undamaged packing. Ship and transport the device only in its original packing.

Right before delivery, the power unit is once again checked for proper functioning and a control mark is attached. When receiving the delivery, check everything for damages and completeness. If damages occurred during transportation or components are missing, inform the manufacturer or the haulier immediately (see page ii).

Proper functioning of the power unit can only be checked before starting-up by visual inspection (visible damage).

The following items are to be observed if the power unit is not to be put into operation immediately after delivery.

– The power unit must be stored in a secure place

– The power unit must be protected against humidity, dust, metallic dirt.

– Storage temperature: -5 °C to +50 °C

– Relative humidity: 0% to 50% at +40 °C

0% to 90% at +20 °C

During transport and set-up of the machine, safety against tilting is only guaranteed up to an angle of 30°.

1.6

A lift unit with two hooks must be used for lifting and transporting the power unit!

In this way, you avoid turning out the ring screws by twisting the machine during lift and transport processes.

Lifting the power unit using the handle or only one ring screw is not permitted.

If you resell the power unit, please provide us with the name and postal address of the new owner so that we can advise them of any changes to the operating manual.

Accompanying Documents

In addition to this operating manual, you must observe the operating manual of the welding gun as well as applicable accident prevention and safety instructions.


13

1 General

1.7 Markings

1.7

Markings

There are various markings and safety symbols attached to your power unit (see section 8.1).

Make sure that all markings remain clearly visible.

Type plate

The type plate contains the following data:

Manufacturer

Type

Order No./Serial No.

Primary voltage

Fuse

Power consumption

Cooling class

Protection class

Date

Safety symbols

Replace illegible or damaged markings

Before opening machine disconnect mains

Observe operating manual

Warning of dangerous electrical voltage

Secure the following safety symbols in the area of welding place:


2 Delivery

The basic equipment of your power unit contains the following components:

No. of pieces Part Type Order No.

1

1

Power unit

Operating Manual

IT 3002

IT 3002

93-66-3211

BA 93-66-3211

2 Delivery


15

3 Starting-up

3.1 Requirements of Workplace

3

3.1

Starting-up

In this chapter you learn what to observe during setting-up and starting-up of the power unit.

Requirements of Workplace

Vapors and airborne particles may occur during stud welding operations. Especially with surface treated materials, toxic vapors may be produced.

Ensure that a fume extraction is available and that the room is adequately ventilated according to accident prevention regulations.

If possible, do not weld in rooms which are lower than 3 meters.

Special regulations apply for confined rooms, according to accident prevention regulations of the official bodies (see appendix).

Weld only in adequate distance from combustible articles or liquids.

Before you start welding, remove any combustible articles or liquids in vicinity of the workplace.

Make sure that a fire extinguisher is within reach.

Never weld in rooms exposed to risk of explosion.

Do not set-up the product in the vicinity of any apparatus or equipment which is sensitive to welding spatters.

Do not set-up the product in the vicinity of any apparatus or equipment which is sensitive to magnetic fields.

Set-up the power unit:

– on a stable, clean, and level surface

– so that no-one is influenced or injured by welding spatters

– so that all cables and primary lines are protected from being damaged

– so that nobody will trip or fall over the cables or connection lines.

Ensure that air is able to circulate freely through the housing.

If heat is built-up inside the housing caused by bad air circulation, the stud welding unit will be seriously damaged.


3 Starting-up

3.2 Connecting the Power Unit to the Primary Power Supply

3.2

Secure the following safety symbols in the area of welding place:

THREAT TO LIFE to persons fitted with a pace maker

Strong electro-magnetic fields occur in the vicinity of the stud welding unit during welding. Such fields may affect the proper function of a pace maker. Thus persons equipped with a pace maker must not operate the stud welding unit and must not stay in its vicinity during welding.

During the actual welding process, you must expect red-hot welding spatters, possibly liquid spatters, a flash, and a loud bang > 90 dB (A).

Alert any colleagues who are occupied in the vicinity of the welder.

Wear your personal protective equipment according to actual standards (see appendix).

Connecting the Power Unit to the Primary Power Supply

Compare the primary voltage specified on the type plate with the voltage provided by your primary power supply. The type plate is located on the backside of the power unit.

Never connect the welder to a power supply with a voltage different from the voltage indicated on the type plate.

Check the current consumption specified on the type plate with the fuse rating of your primary power supply.

Have an electrician check whether the outlet to which you want to connect the power unit is correctly grounded.

Switch off the power unit.

Insert the primary plug into the checked outlet.


17

3 Starting-up

3.3 Connecting the Welding Gun to the Power Unit

3.3

Connecting the Welding Gun to the Power Unit

Switch off the power unit. In this way, you avoid any risk of electrical shock.

Plug the welding cable of the welding gun into the socket of the power unit.

Press-in the plug and twist firmly clockwise.

The connection is not secured against working itself loose!

Check the plug connections regularly to ensure that they are properly locked. In case of loose connection, heat may build up in the plug and may destroy the entire plug connection.

Plug the control cable in the connector of the power unit.

Twist the retaining nut of the control cable connector clockwise to secure the connection.

The welding gun cables must not be coiled during welding.

Coiled cables work as a coil and may negatively affect the welding result. Before welding, lay out the cables lengthwise.

Fix the cables. Strong magnetic fields occur during welding which may cause a movement of the cables. This may cause a slackness of the connections.


3.4

Ground Connection

Plug the ground cable in the connector of the power unit.

3 Starting-up

3.4 Ground Connection

Press in the plug and twist firmly clockwise.

The connection is not secured against working itself loose!

Check the plug connections regularly to ensure that they are properly locked. In case of loose connection, heat may build up in the plug and may destroy the entire plug connection.

Remove any rust, paint, or contaminants from the workpiece in the areas where you intend to connect the ground cables.

Connect the ground clamps to the workpiece as securely as possible.

3.5

Take care to ensure good contact and symmetrical connection.

The welding location must lie directly between the two ground clamps.

Change Working Place

Switch off the power unit. In this way, you avoid any risk of electrical shock.

When you move your workplace, disconnect the welding gun and the ground cables from the power unit. Proceed in reversed sequence as described in sections 3.2, 3.3 and 3.4.

After changing the workplace, check the welding gun and the ground cables for possible damage or missing components.


19

4 Function

4.1 Components of the Power Unit

4

4.1

Function

In this chapter you learn more about the design of the power unit and how to use the various setting options.

Components of the Power Unit

4.1.1

Power Unit

20

The power unit consists of the main assemblies

1 - Mains switch 6 - Control unit

2 - EMC-filter

3 - Bridge rectifier

7 - IGBT switch

8 - Middle-frequency transformer with diodes

4 - Electrolytic capacitors

5 - Control unit

9 - Welding current stabilizer

After passing the mains switch (1) and the EMC-filter (2), the mains alternating current is converted in the bridge rectifier (3).

The rectified voltage is smoothed by the electrolytic capacitors (4) and transferred to the IGBT switches (7). These switches convert the direct current into a high-frequency alternating current of 30 kHz.

The energy is transferred via the middle-frequency transformer with diodes (8) and rectified.

The stabilizer (9) smoothes the current and passes it on to the welding sleeves.

Control of the IGBT switches (7) is carried out by the control unit (6).


4 Function

4.2 Keyboard and Display

4.1.2

Control Unit

The control unit synchronizes the mechanical sequence (lifting the welding element) with the electronic control (ignition of pilot arc, ignition of main arc, sequence of welding time). The welding time is stepless adjustable.

4.2

Keyboard and Display

How to use displays and keys is described in section 5.6.


21

5 Stud Welding Procedure

5.1 Safety Instructions

5

5.1

Stud Welding Procedure

This chapter contains the basics of stud welding, how you must actually proceed, and what must be observed. You learn to select correct welding parameters and which welding elements can be used.

Safety Instructions

Improper operation of the power unit is LIFE-THREATENING!

Threat to life

– by electric shock and arc

– by toxic vapors and airborne particles

– by red-hot metal spatters (fire risk)

– by blow-up of explosive gases and materials

– during welding of hollow parts

– by strong magnetic fields to persons fitted with a pace maker

THREAT TO LIFE by electrical shock and arc

During the actual stud welding process, do not touch the welding elements, chuck, or retaining nut nor any electrically conductive parts in their vicinity. These are all electrically life.

Step onto an insulating mat, if you have to weld under the following conditions:

– in confined rooms with electrically conductive walls

– under confined conditions between or on electrically conductive parts

– with restricted freedom of movement on electrically conductive parts

– in wet or hot areas

When operating the stud welding unit, you must not wear any metallic jewellery incl. wristwatches, especially on hands. Remove any electrically conductive or electro-magnetically sensitive parts from your body before you start welding. In this way, you avoid the risk of damage by electric shock or influence of electromagnetic fields.




THREAT TO LIFE by toxic vapors and airborne particles

Toxic vapors and airborne particles may occur during stud welding operations, especially with surface treated materials.

Ensure that a fume extraction is available that the room is adequately ventilated according to accident prevention regulations.

If possible, do not weld in rooms which are lower than 3 meters. Special regulations apply for confined rooms according to accident prevention regulations of the official bodies of your country (see appendix).

THREAT TO LIFE by red-hot metal spatters (fire risk)

Make sure that a fire extinguisher is within reach.

Do not wear clothes, which are contaminated with combustible materials like oil, grease, kerosene etc. during welding.

Always wear your personal protective equipment such as:

– protective gloves to current standards (see appendix),

– safety goggles with a window providing protection class 2 to current standards (see appendix),

– non-combustible clothes

– ear protection to current standards (see appendix),

– a protective apron over your clothes,

– a protective headgear when welding overhead.

Before starting to weld, remove all combustible articles and liquids in vicinity of the workplace.

Weld only in sufficient distance from combustible articles or liquids.

choose a safety distance where there is no risk to injury from welding spatters!

THREAT TO LIFE by blow-up of explosive gases and materials

Never weld in rooms exposed to danger by explosion.

Special know-how is required when welding hollow parts which

– are combustible or support combustion,

– can emit toxic gases, vapors, or airborne particles,

– can explode.

Never execute such operations, if you do not have such special knowhow.

Observe the regulations for accident prevention and standards which apply to the use of your stud welding unit (see appendix).

The official Professional Association of your country will provide you with further information.

Please note that in your country additional standards and safety conditions (especially rules for accident prevention) may differ

from the standards mentioned in this operating manual.


23



THREAT TO LIFE to persons fitted with a pace maker

Strong electro-magnetic fields occur in the vicinity of the stud welding unit during welding. Such fields may affect the proper function of a pace maker. Thus persons equipped with a pace maker must not operate the stud welding unit and must not stay in its vicinity during welding.

During the actual welding process, you must expect red-hot welding spatters, possibly liquid spatters, a flash, and a loud bang > 90 dB (A).

Alert any colleagues who are occupied in the vicinity of the welder.

Wear your personal protective equipment according to actual standards (see appendix).

MAGNETIC FIELDS!

During stud welding, strong magnetic fields are present. Do not weld in the vicinity of electrical systems and machines which could be affected.


In case of any accidents whatsoever, advise a physician, your supervisor, and the official bodies immediately.



5.2 Functional Principle of Stud Welding

5.2

Functional Principle of Stud Welding

The face of a stud-shaped welding element and the opposite surface of the workpiece are molten by an arc. Stud welding is suitable for the welding of joining elements across the entire cross-section, mainly using pin-shaped metallic welding elements with metallic workpieces.

The various processes of arc stud welding are distinguished by:

– The method of weld pool protection (shielding gas - SG, ceramic ferrule - CF or no protection - NP)

– The length of welding time (standard ARC or short-cycle drawn-arc stud welding -

SC)

– The energy source (welding rectifier supplied by mains, inverter, capacitor battery)

Variations for drawn-arc ignition are described in current standards and regulations

(see appendix).

Drawn-Arc Stud Welding

The HBS stud welding unit operates by process of ‘arc stud welding with drawn-arc ignition’ according to the current standards (see appendix). The standards assign this method of joining pin-shaped elements with plane workpieces to the so called ‘Arc

Pressure Welding’ (code BH).

Joining is carried out in plastic or liquefied condition of the welding zone. The process can be carried out mechanically or automatically, depending on the used welding guns/ welding heads.

Generally, the positive pole of the power unit is connected to the workpiece. The welding element is manually or automatically inserted into the chuck of the welding gun or of the welding head. Then it is placed onto the workpiece - possibly equipped with a ceramic ferrule (see position 1). When the button of the welding gun is triggered, the automated welding process starts, which works as follows:

Pre-flow of shielding gas depending on set pre-flow time (only with shielding gas for weld pool protection).


25



– At the beginning of the welding process, the welding element (stud) in the welding gun is lifted clear off the workpiece by a lifting device (solenoid). An initial switched current triggers a pilot arc of a low current power (see position 2). Then the main arc ignites between the face area of the welding element and the workpiece.

– The main arc burns at the set current during the welding time preselected at the power unit. The selected welding energy must match the requirements of the selected welding element. The energy of the arc melts the face of the welding element and the workpiece (see position 3).

– At the end of the preset welding time, the stud is mechanically moved to the workpiece. On plunging into the weld pool, the two weld zones join and solidify. The contact of stud and workpiece extinguishes the arc in a short-circuit and the main current is switched off.

– The weld zone solidifies and cools down. The welding element is now welded to the workpiece over its entire cross-section of the welding element (see position 4). As soon as the weld metal is cooled down, the welding gun can be carefully withdrawn from the welding element. When using shielding gas, the shielding gas flow is switched off with the withdrawal of the welding gun. If a ceramic ferrule is used, it can be removed by light hammer blows.

The welding range of drawn-arc stud welding is about 3 to 25 mm diameter when using mild steel/stainless steel. Welding elements with rectangular cross-section should not exceed a ratio length : width of about 5 : 1. All technical information and adjustment values are based on the use of welding elements which correspond with current standards (see appendix).

Variants of drawn-arc stud welding

Item

Diameter welding element d

[metric mm (imperial)]

Max. current I [A]

Welding time t [ms]

Energy source

Weld pool protection

Drawn-arc stud welding with ceramic ferrule/ring

3 - 25

(#4 or 12 gage to 1")

3000

50 - 2000

Welding rectifier

Welding transformer

Ceramic ferrule CF

Material welding element

S 235

CrNi steel

Aluminum (up to 12 mm/0,47")

Metallic bright Workpiece surface

Min. thickness of workpiece

(rolling skin, rust film)

¼ d min. 1 mm (0,04")

Adjustable parameters Welding current

I [A] = 80 x d

(up to 16 mm/0,63")

Welding time t [ms] = 20 x d

(up to 12 mm/0,47")

Lift

(arc length)

Plunging depth

Drawn-arc stud welding with shielding gas

3 - 12 (16)

(#4 or 12 gage to 1/2" (5/8")

Short-cycle stud welding with shielding gas

3 - 12

(#4 or 12 gage to 1/2")

Capacitor-discharge stud welding with drawn-arc

2 - 8

(14 gage to 5/16")

2500

50 - 2000

Welding rectifier

Welding transformer

Shielding gas SG

1500

5 - 100

Welding rectifier

5000

3 - 10

Capacitor

S 235

CrNi steel

Aluminum (up to 12 mm/0,47")

Metallic bright

(rolling skin, rust film)

1/8 d min. 1 mm (0,04")

Welding current

I [A] = 80 x d

(up to 16 mm/0,63")

Welding time t [ms] = 20 x d

(up to 12 mm/0,47")

Lift

(arc length)

Plunging depth

Shielding gas SG

No protection NP

S 235

CrNi steel

Brass (with shielding gas)

Metallic bright, galvanized, light oiled

1/8 d min. 0,6 mm (0,02")

Welding current

I [A] = 100 x d

(up to 12 mm/0,47")

Welding time

Lift

(arc length)

Plunging depth

No protection NP

S 235

CrNi steel

Aluminum, brass, copper

Metallic bright, galvanized, light oiled

1/10 d min. 0,6 mm (0,02")

Charging voltage

Ignition point / lift

Spring pressure

(plunging speed)

Plunging depth




5.2.1

Drawn-Arc Stud Welding with Ceramic Ferrule

Drawn-arc stud welding with ceramic ferrule is used with welding elements of 3 to 25 mm diameter (preferably above 12 mm diameter) and with welding times of 50 to

2000 ms. It is generally suitable for all welding positions. When stud welding with ceramic ferrule, the welding position is PA (vertical). The major part of all applications applies to this procedure.

The ceramic ferrule (CF)

– prevents atmosphere from getting to the weld pool by a formation of metal vapor in the arc chamber

– stabilizes and concentrates the arc, thus decreasing the arc blow effect

– forms the melt under pressure to a weld collar and supports the weld pool on a vertical wall and overhead

– protects the welder from arc radiation and welding spatters.

Normally, the ceramic ferrule is used for only one weld and is removed after solidification of the weld pool.

Standard welding elements and ceramic ferrules are described in several standards (see appendix). When using concrete anchors or shear connectors the front area can be plane constructed with a small pressed-in aluminum ball.

Studs with cone-shaped front area and aluminum ball ceramic ferrule.

are preferably used with


27



5.2.2

Drawn-Arc Stud Welding with Shielding Gas

Drawn-arc stud welding with shielding gas is used with welding elements for a diameter range of 3 to 12 (16) mm and with welding times from 50 to 2000 ms. Principally, it is suitable for all welding positions, however, it is preferably used in vertical position PA.

With stud welding with shielding gas, the weld area is protected by shielding gas. The shielding gas, which is fed from outside through a gas control and an additional device, displaces the ambient atmosphere from the welding area and reduces considerably pore formation.

With steel and CrNi steel, the gas mixture 82% Ar and 18% CO

2

(DIN EN ISO 14175 – M21) is mainly used.

With aluminum, pure argon Ar 99,99 (DIN EN ISO 14175 – I1) or

Ar-He mixtures (DIN EN ISO 14175 – I3) are used.

The shielding gas influences

– the arc and the melting behavior of welding element and workpiece,

– the development of the weld collar and the penetration shape via the surface tension.

With stud welding with shielding gas, the shape of the weld collar is not reproducible, as the shielding gas has no forming effects on the melt – different from a ceramic ferrule.

And so an additional ceramic ferrule may be used in special cases.

The standard welding elements and ceramic ferrules for drawn-arc stud welding are described in several standards (see appendix). Welding elements with cone-shaped front area and without an aluminum ball are preferably used.

Studs with cone-shaped front area preferably used under shielding gas.

With shielding gas, you should only weld in position PA (vertical) because due to gravity, the shielding gas cannot prevent flow of the molten metal.




5.2.3

Short-Cycle Drawn-Arc Stud Welding with Shielding Gas

Short-cycle drawn-arc welding with shielding gas is used for welding elements within a diameter range of 3 to 12 mm (nominal diameter without flange) and welding times between 5 and 100 ms.

Due to the short welding times, the energy input and the weld pool are so small that also welding elements up to 12 mm diameter can be welded on thin workpieces.

Normally, welding elements with flange (according to current standards, see appendix) are used, which forms a larger welding area compared with the shaft diameter. In this way, higher tensional forces than in the stud shaft can be transmitted in spite of some pores in the weld zone. To minimize pore formation, the use of shielding gas for stud diameters upwards of 8 mm is recommended.

5.2.4

Drawn-Arc Capacitor-Discharge Stud Welding

With drawn-arc capacitor-discharge stud welding, the welding energy is taken from a capacitor. As a result, welding currents are very high and welding times (< 10 ms) very short. Normally, a weld pool protection is not required. The process is mainly used for welding elements in a diameter range of up to 8 mm.


29


5.3 Welding Preparation

5.3

5.4

5.5

Welding Preparation

Read the safety instructions in chapters 1, 3 and 5.

Observe the workplace requirements (chapter 3, ”Starting-up").

Check all cables and connections for proper condition.

Replace immediately defective cables and cable connections to avoid electrical shocks.

Check the chuck for proper seat (see operating manual of according welding gun).

Before welding, make sure that the bellows are checked for damage and proper seat.

High-strength Welds

The following must be removed both from the weld zone and the ground clamp connection areas:

– paint, oil and any other impurities,

– rust,

– non-conductive coatings from surface treated workpieces.

Weld to smooth and flat surfaces only.

For welding to pipes or punched plates consult our responsible application manager (address of customer service see page ii).

Determination of Welding Parameters

Required welding data depend on stud diameter in welding area, on welding position, on type of weld pool protection, on process variant, on plate material, on plate thickness and on design of weld tip. Consequently, optimum data for your application may differ from given nominal values.

Data given in the following table are only guidelines. They must be verified by trial welds on the actual material according to actual standards and DVS guidelines (see chart and appendix).

Before you use another lot of welding elements, carry out some trial welds to verify the parameter setting.

For an assessment of welding results, see sections 5.8 and 5.9.



5.5 Determination of Welding Parameters

The work of the arc (W = U x I x t) is used to melt stud and plate. The values Welding

Current I and Welding Time t can be replaced by the other welding parameter within certain limits. In this way, different nominal data diagrams are created which are used in respective national regulations on stud welding.

Allocation of stud diameter to current and time

(DIN EN ISO 14555)

Nominal values of welding current and welding time in position PA can be determined according to DIN EN ISO 14555 using the following equations:

I [A] = 80 x d [mm] for stud diameters up to 16 mm

I [A] = 90 x d [mm] for stud diameters above 16 mm t [ms] = 20 x d [mm] for stud diameters up to 12 mm t [ms] = 40 x d [mm] for stud diameters above 12 mm

Allocation of stud diameter to current, time, lift and protrusion

(DVS Technical Bulletin 0902)

The given values apply to weldings in the welding position PA. The welding time shall be reduced for welding in the welding position PC.

When welding alloyed steel, a 10% lower current is normally selected.

In the case of short cycle stud welding, the welding time is less than 100 ms. It depends not only on the stud diameter, but also on the available current intensity

(I[A] = min. 100 x Ø (mm)). The welding time should be as short as possible in the case of welding without weld pool protection. Welding energy is only selected by welding time.


31


5.6 Switching on the Power Unit

Allocation of stud diameter to current, time, lift and protrusion

(ANSI/AWS C5.4)

11,1

12,7

15,9

19,1

22,2

25,4

Stud Base Diameter

mm

6,4 inch

0,25 (1/4)

7,9

9,5

0,31 (5/16)

0,37 (3/8)

0,44 (7/16)

0,50

0,88

1,00

(1/2)

0,62 (5/8)

0,75 (3/4)

(7/8)

(1)

Welding Downhand

PA

Current Time

A s

450

500

550

0,10

0,25

0,33

675

800

0,42

0,55

1200

1500

1700

1900

0,67

0,84

1,00

1,40

Lift

mm

1,6

1,6

1,6

1,6

1,6

2,4

2,4

3,2

3,2

Protrusion

mm

3,2

3,2

3,2

3,2

3,2

4,7

4,7

6,4

6,4

Welding Overhead

PE

Current Time

A s

450

500

550

0,17

0,25

0,36

675

800

0,42

0,55

1200

1500

1700

2050

0,67

0,84

1,00

1,20

Lift

mm

1,6

1,6

1,6

1,6

1,6

1,6

1,6

1,6

1,6

Protrusion

mm

3,2

3,2

3,2

3,2

3,2

4,7

4,7

6,4

6,4

Welding to a Vertical Surface

PC

Protru-

Current Time

A s

450

500

600

750

875

1275

0,17

0,25

0,33

0,33

0,46

Lift

mm

1,6

1,6

1,6

1,6

1,6

0,60 1,6

Not Recommended

Not Recommended

Not Recommended

sion

mm

3,2

3,2

3,2

3,2

3,2

4,7

When welding alloyed steel, a 10% lower current is normally selected.

Further notes on

– welding elements

– prestress at installation (tie load) and torque

– material combinations see appendix and operating manual of the according welding gun.

5.6

Switching on the Power Unit

Improper operation of the stud welding unit is

LIFE-THREATENING!

First read the safety instructions in chapters 1, 3 and 5.

Insert the primary plug of the power unit into an appropriate socket.

Switch on the power unit with the mains switch.




The digital display shows the adjusted welding time and welding current.

There is a luminous indication (LED) to the right of the display:

Yellow – lights if the welding gun button is triggered

Yellow – lights if there is electrical contact between welding element and workpiece

Red – on, power unit is locked

• after welding, until there is electrical contact with the workpiece

Green – on, power unit is ready for welding


• if the power unit is overheated (displays show 8888 and

LED lights).

After a short cooling period, the work can continue.


• if the power unit is overheated

• if there is a malfunction of the power unit

5.6.1

Adjusting the Welding Time

Set the welding time (digital display ) with the arrow keys

(

⇑ longer – ⇓ shorter) on the display.

5.6.2

Adjusting the Welding Current

Set the welding current (digital display

( ⇑ higher – ⇓ lower) on the display.

) with the two arrow keys


33



5.6.3

Library Mode

In the library mode, you can call up and modify charging voltages, depending on stud diameter (UD/pins).

Simultaneously press both arrow keys of welding time (

⇓ shorter ⇑ longer) for about one second. The display welding time shows 0-06 (06 means the set welding current and welding time for stud diameter of 6 mm).

You can pre-select the stud diameter (6 mm to 25 mm) with both arrow keys

(

⇓ shorter ⇑ longer). After about 3 seconds the display (

) jumps onto the pre-selected welding time and the display ( ) onto the pre-selected welding current.

In addition, you can modify the welding time and welding current individually by pressing the arrow keys (as described above).

If you are working with shielding gas, different welding parameters for stud diameters (from 6 mm to 12 mm) are available in library mode.

5.6.4

Conversion Current Curve

It is possible to adjust the current curve for a special welding method. There is a difference between drawn-arc stud welding with ceramic ferrule or with shielding gas.

Drawn-arc stud welding with ceramic ferrule

Simultaneously press both arrow keys (welding current

⇓ higher ⇑ lower) for about one second. The display welding current shows the current scale with dots.

1.9.4.0.

Drawn-arc stud welding without ceramic ferrule

Simultaneously press both arrow keys (welding current

⇓ higher ⇑ lower) for about one second. The display welding current shows the current scale without dots.

1 9 4 0



5.7 Welding Procedure

5.7

Welding Procedure

Improper operation of the stud welding unit is

LIFE-THREATENING! The stud welding unit must only be operated by qualified personnel (see chapter 1).

Observe the safety instructions in chapters 1, 3 and 5.

Prepare the stud welding unit, the ground connection, and the workpiece according to the instructions given in the operating manual.

Chapter 5 contains guideline for welding parameters. The data given are only guidelines. They must be verified by trial welds on the actual workpiece according to actual standards and DVS regulations (see appendix).

During the actual welding process, you must expect red-hot welding spatters, possibly liquid spatters, a flash, and a loud bang may occur

> 90dB (A). Inform any collegues who are occupied in the vicinity of the welder about the bang.

Wear always your personal protective equipment according to actual standards (see appendix).

Insert the welding element into the chuck.

As soon as the power unit is ready for the welding process,

place the welding gun vertically against the workpiece,

push the welding gun firmly with both hands onto the workpiece until the welding gun support (distance device) is evenly seated on the workpiece,

hold the welding gun firmly, still, and straight,

take care that you do not touch any metallic part of the welding gun,

press the trigger button of the welding gun.

This initiates the welding process.

The welding process can only be initiated, if the current circuit is closed, i.e. the welding element is in electrical contact with the base material.

After the welding process has been completed, withdraw the welding gun straight back from the welding element. If you remove the welding gun at an angle, the chuck will be stretched, this reduces its life expectancy.

You can now insert a new welding element in the chuck and repeat the welding process as described above.


35


5.8 Checking the Quality of the Weld

5.8

Checking the Quality of the Weld

You can check the quality of the weld by means of a visual inspection and a bending test.

See also actual standards in the appendix “Arc stud welding of metallic materials“, in section irregularities and corrective actions.

5.8.1

Visual Inspection

A visual inspection must be carried out with each welding element.

Shape, size, evenness, and color of the weld collar are assessed during a visual inspection. The length of a welded element should be 2 to 3 mm shorter than before welding.

Condition

Weld collar evenly, shiny, and complete

Visual Inspection

Possible cause

- Correct parameters

Corrective actions

- None

Length of w elding element w ithin tolerance after w elding

Contraction of w eld collar w elding element too long

- Plunging depth or lift too low

- Welding energy too high

- Ceramic ring not centered correctly

Weakly developed, uneven w eld collar w ith mat surface

- Welding energy too low

Welding element too long - Ceramic ring is humid

- Increase plunging depth, check lift and

centering of the ceramic ring

- Decrease current and/or time

- Check centering

- Increase current and/or time

- Rebake ceramic rings in a furnace

Single-sided w eld collar

Undercut

- Arc blow effect

- Ceramic ring not centered correctly

Weld collar low , shiny surface w ith many spatters

Welding element too short

- Welding energy too high

- Plunging speed too high

- See arc blow effect

- Check centering

- Decrease current and/or time

- Adjust plunging depth and/or damping factor




5.8.2

Bending Test

You can purchase from HBS a bending device with inserts for various diameters of the welding elements.

The bending test serves as an easy work sample and as a check for the selected welding parameters. The welded joint is stressed by bending in a non-defined way.

Bend the welding element with the bending device once by 60°.

Carry out the test in different directions.

The bending test is passed if a crack or a fracture of the welded zone does not occur.

Please note the instructions on fault recognition and corrective actions in chapter 5.

You don’t need to test all studs. It is sufficient to carry out stud tests at random.

If the strength of the joint is inadequate, then:

check the setting of the stud welding unit

check whether the surface of welding element and base material are clean and electrically conductive (must be free from scale, oil, paint, oxide layers)

grind off hardened workpiece surfaces (e.g. roll hardening).

Check the piston of the welding gun for ease of movement.


37



Type of fracture

Base material buckling

Bending Test

Possible cause

- Correct parameters

Corrective actions

- none

Fracture in welding element above weld collar

- Correct parameters - none

Fracture in the weld metal

Many pores

Fracture in the weld metal

Shiny fracture surface

- Welding energy too low

- Plunging speed too low

- Unsuitable stud/base

material combination

- Welding time too short

- Increase welding energy

- Increase plunging speed

- Replace welding element or workpiece

- Increase welding time




5.8.3

Arc Blow Effect

A so called arc blow effect can occur with unproportionally distributed ground connections in relation to the base material mass, varying material distribution, or welding at the edge of a workpiece. This is an undesired deflection of the arc. It causes a single-sided melting of the stud material, increased pore formation, and undercuts in the welding area.

The arc blow effect is proportional to the current and can be influenced by symmetric installation of the ground clamps, by fitting of compensation masses, or by rotating the welding gun around its vertical axis (applies for welding guns with external welding cable).

Arc blow effects and some corrective actions

(according to standards, see appendix)

Cause Corrective action


39


5.9 Malfunctions and Corrective Actions

5.9

Malfunctions and Corrective Actions

Malfunction

Primary switch does not rest in position 1

Possible cause

Primary switch defective Check mains switch *)

No LED display at the front

No C-display

Fuse F4 1 AF for mains switch defective

Mains cable defective

Fuse F5 1 AF defective

No ground connection

Fault finding

Check voltage supply of mains switch

*)

Check mains cable for breaks *)

Check fuse F5 1 AF *)

Check ground connection on workpiece

Check welding gun connection

Corrective action

Replace mains switch *)

Replace fuse F4 1 AF *)

Replace mains cable *)


Carried out by

Qualified personnel

Qualified personnel

Qualified personnel

Tighten ground connection properly Qualified personnel

Connect welding gun properly

Qualified personnel

Instructed personnel Welding gun not connected

Transition resistance

(between stud and workpiece) too high

Ground cable broken

Check material surface

Check ground cable *)

Clean or grind material surface

Replace ground cable *)

Instructed personnel

Qualified personnel

Welding gun cable broken Check welding gun cable *) Replace welding gun cable *) Qualified personnel

No display

Continuously red display:

Display 8888

Defective connecting line of welding gun

Check function of connecting line *) Replace connecting line *) Qualified personnel

Welding gun trigger button defective

Check control cable for electrical flow with triggered start button *)

Control cable broken Check control cable for electrical flow

*)

Welding sequence too fast Power unit resets automatically

Replace welding gun trigger button

*)

Replace control cable *)

Let switched on power unit cool down, power unit resets automatically

Qualified personnel

Qualified personnel


Welding gun does not lift, in spite of and

No lift adjusted

Short circuit of solenoid circuit of the welding gun

Check settings of welding gun

Check resistance value of control cable (18 Ω to 22 Ω) between Pin 1 and Pin 2 *)

Lifting impossible

Modify set parameters

Replace control cable plug, control cable, solenoid *)


Qualified personnel

Solenoid defective

Fuse F3 4 AF defective

Check solenoid (18 Ω to 22 Ω) *)

Check fuse F3 4 AF *)

Replace solenoid *)


Qualified personnel

Qualified personnel

Solenoid circuit interrupted Check resistance value at control cable plug (18 Ω to 22 Ω) between Pin

1 and Pin 2 *)

Replace solenoid or control line *) Qualified personnel

Actions marked with *) must only be carried out by qualified electricians!

If none of the actions is successful, please contact our service department.



5.10 Welding Elements

5.10

Welding Elements

The stud welding unit must be suitable for welding the welding elements to be used.

Observe the instructions in the operating manuals.

Welding elements are mainly manufactured with the cold formed process.

We recommend the following standard welding elements (see appendix).

Use only welding elements of the same lot. Take particular care not to mix-up different lots. Slightest variations in geometry of the welding elements, especially of the ignition tip, require modified settings of the welding process.

Threaded stud RD (MR) Diameter Length

M6

M8

M10

M12

M16

15-40 mm

15-50 mm

20-55 mm

25-60 mm

30-65 mm

Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303

Threaded stud DD (MD) Diameter Length

M6

M8

M10

M12

M16

Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303

15-30 mm

15-50 mm

20-55 mm

25-60 mm

30-65 mm

Threaded stud PD (MP) Diameter Length

M6

M8

M10

M12

M16

Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303

15-40 mm

20-50 mm

20-160 mm

25-160 mm

30-160 mm

* Please use only welding elements without aluminum ball.


41



42

Pin UD (S) Diameter Length

6

8

10

12

16

Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303

20-50 mm

20-50 mm

20-80 mm

20-80 mm

25-80 mm

Pin with internal thread MI (ID) Diameter

M10

M12

M16

Length

20-50 mm

20-50 mm

20-50 mm

Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303

Head stud SD Diameter Length

1/4" (6)

3/8" (10)

1/2" (13)

5/8" (16)

3/4" (19)

7/8" (22)

1" (25)

Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303

50-100 mm

50-175 mm

50-175 mm

50-175 mm

50-175 mm

75-200 mm

75-215 mm

Ceramic ferrule RF for threaded stud RD

Diameter

6

8

10

12

16

Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303

* Please use only welding elements without aluminum ball.




- Ceramic ferrule PF for threaded stud PD

- Ceramic ferrrule UF for pins UD, MI

Diameter

6

8

10

12

16

Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303

Ceramic ferrule UF for head stud SD Diameter

1/4"

3/8"

1/2"

5/8"

3/4"

7/8"

1"

Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303

Threaded stud FD with flange

Diameter

M3

M4

M5

M6

M8

Materials: S235 / St37.3k (4.8) / 1.4301

Length on request on request on request on request on request

X-mas tree stud Diameter

5

6

Length on request on request

Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303

We look forward to consult you with view to special welding elements and other special materials.


Felix-Wankel-Strasse 18

85221 Dachau / Germany

Phone +49 (0) 8131 511-0

Fax +49 (0) 8131 511-100

E-mail [email protected]


43

6 Switching off the Power Unit

6.1 Temporary Switching off

6

6.1

6.2

Switching off the Power Unit

This chapter describes what you should observe when you switch off the power unit temporarily or completely.

Temporary Switching off

Switch off the power unit.

Unplug the control cable and the welding cable from the power unit.

Protect the power unit against ingress of fluids and foreign bodies.

Disposal

If you shut down the installation, you can return the complete power unit to HBS

(for address see page ii).

We will take care of environmentally correct material separation and disposal.


7 Care and Maintenance



7.1

7.2

7.3

Safety Instructions

Let maintenance and repair operations be carried out only by qualified personnel or by your competent service technician.

Before starting any repair or maintenance operation, always switch the power unit off and disconnect the primary plug.

Do not wear a wristwatch or any electrically conductive jewellery.

Regular Maintenance Operations

Clean the inner components of the power unit periodically of dust. Use a dry washcloth or a brush. To open the power unit, proceed as described in sections 7.1, 7.3 and 7.4.

Clean the surface of the power unit with a humid washcloth and a detergent.

Do not use any solvent containing cleaning agents. Solvent containing cleaning agents may damage the surface of the power unit.

Tools to be Used

– Allen key, size 4


45


7.4 Open the Power Unit

7.4

Open the Power Unit

Open the power unit only if you are sufficiently qualified in repairing electrical equipment.

Remove the 8 screws (2 at each side and 4 on top) and 2 eye bolts on the casing cover.

Lift carefully the casing cover and remove the ground conductor from the inside of the cover.

Now pull off the cover from the power unit.

Remove the 14 screws of the two side plates.

Remove carefully the side plates and remove the ground conductor from the inside of the cover.

46

Re-assemble the power unit in reverse sequence.

Make sure that no cables are jammed or sheared during assembly.


8 Appendix

8.1 Technical Data

8

8.1

Appendix

In the appendix, there is information of interest regarding technical data, spare part lists, accessories, standards, etc.

Technical Data

Power unit type IT 3002 for ARC stud welding according to current standards

Welding range

Welding material

Welding rate

Welding current

Current adjustment range

Welding time

Primary power

#4 to 1”, dia. 14 ga to 1”

(M3 to M24, dia. 2 to 25 mm)

Mild steel, stainless steel, aluminum

Dia. 1” = 6 studs/min. (dia. 25 = 6 studs/min)

Through deck welding:

3/4” = 12 suds/min.

(300 feet, AWG 4/0)

Industrial application:

3/4” = 14 to

15 studs/min.

2,600 A (max.)

300 to 2,600 A (stepless)

5 to 1,500 msec (stepless)

480/460 V, 3 phases, 50/60 Hz, 125 AT

(alternative input voltages available)

Connected load

Cooling type

Protection class IP 23 (also permits operation outdoors)

Operational and storage conditions According to current standards

Dimension L x W x H

Weight

150 KVA (with 400 V mains voltage), 120 kW

F (temperature controlled cooling fan)

25.6” x 22.0” x 50.8” (650 x 560 x 1,290 mm) without handle

352.7 lbs (160 kg)


47

8 Appendix

8.2 Spare Parts

8.2

Spare Parts

Spare part list power unit type IT 3002 (93-66-3211)

When ordering spare parts, please indicate order number and type of power unit.

Quantity

1

1

1

2

1

1

4

4

1

1

1

1

1

1

1

1

1

1

1

1

15

19

17

6

4

2

3

3

5

3

1

1

1

1

5.0 m

Pos.

16

17

19

21

23

26

28

30

34

36

9

10

11

13

15

5

7

8

1

3

52

54

56

58

61

38

40

42

44

46

102

104

106

108

110

Order No.

80-11-499

80-90-121

80-90-110

80-90-153

80-90-195

80-10-0996

80-11-567

80-11-560

80-10-0998

80-50-5590

80-90-147

80-90-114

80-90-446

80-90-121

80-90-110

88-17-910

88-17-904

88-15-164

88-17-903

88-17-437

88-17-931

88-15-191

88-15-192

88-15-190

80-11-754

88-17-921

80-10-1144

80-10-1143

80-90-155

80-10-857

80-80-558133

80-11-415

88-11-784

88-15-170

80-50-0438

Description

Basic assembly complete

Front plate complete

Rear wall complete

Control unit complete

Ground connection

Welding current connector

Side panel right

Side panel left

Cover

HBS Logo small 37x28

Country module USA complete

Label mat white

Label mat black

Eyebolt M10

Handle A=300

P.C. board

Distance stud 6K-10 M3

Distance sleeve 8 x 13

Board support complete

Synchronizing component

Distance stud M4

Spring washer 4 mm

Screw M4 x 8

Nut M4

Screw M4 x 6

Screwed cable connection

Lock nut M25 x 1.5

Blind plug M25 x 1.5

Lock nut M32 x 1.5

Mains cable

Spring washer 6 mm

Screw M6 x 10

Screw M6 x 10

Spring washer 4 mm

Screw M4 x 8


122

124

128

129

130

112

114

116

119

120

132

136

138

160

3

3

2

3

1

1

4

2

3

2

6

4

4

3

80-90-455

80-90-153

80-90-378

80-11-121

80-90-274

80-90-473

80-90-474

80-90-295

80-90-217

80-90-294

80-90-458

80-90-163

80-90-145

80-10-159

Washer 4 mm

Nut M4

Screw M4 x 14

Flat connection

Washer 17 mm

Tooth lock washer A16

Screw M16 x 30

Spring washer 10 mm

Washer 10 mm

Screw M10 x 25

Screw M10 x 35

Screw M6 x 16

Screw M5 x 16

Cap

8 Appendix

8.2 Spare Parts


49

8 Appendix

8.2 Spare Parts

50

4

6

3

4

6

49

48

16

4

4

3

2

1

4

2

0.45 m

0.50 m

11

2

22

1

1

1

1

1

1

4

1

4

2

Quantity

1

1

1

1

2

80-90-147

80-90-296

80-90-319

80-90-217

80-90-295

80-90-294

80-90-164

80-90-135

80-90-150

80-90-140

88-18-011

80-50-035

80-10-0620

80-11-806

80-10-0978

80-10-610

80-10-0633

80-10-777

80-90-370

80-90-198

Order No.

88-15-135

88-15-142

88-15-144

88-15-222

88-15-167

88-15-145

88-15-159

88-15-160

88-15-168

88-15-162

88-15-161

88-16-641

80-50-049

80-50-927

80-50-0071

Spare part list basic assembly complete IT 3002 (88-17-910)

134

136

138

142

144

124

126

128

130

132

73

77

110

120

122

57

59

65

69

71

25

26

45

49

55

11

15

17

21

23

Pos.

5

7

9

1

3

Description

Bottom plate complete

Stop washer 30 x 6,5

Support plate

U-support plate

Stiffening support

Fan support complete

Contact socket

Conductor connection rail

Spacing leg 25,5 x 20

Power element support

Ground connection rail

Connector

Fan

Mains interference filter

Mains switch

Clamping jaw complete

Mounting sleeve

Slotted hole sleeve

Air wheel

Guide roll

Mounting rail punched

Cable channel 31 x 63

Cage nut KM6

Screw M6 x 16

Washer 6 mm

Spring washer 6 mm

Screw M6 x 12

Screw M4 x 8 black

Washer 10 mm

Spring washer 10 mm

Screw M10 x 25

Washer 4 mm

Screw M4 x 35

Washer 8 mm

Spring washer 8 mm


156

158

160

162

168

146

148

150

152

154

170

2

6

6

2

5

2

4

3

3

2

1

8 Appendix

8.2 Spare Parts

80-90-416

80-90-141

80-90-280

80-90-121

80-90-153

80-90-342

80-90-289

80-90-146

80-90-142

80-11-359

80-11-358

Screw M8 x 30

Nut M8

Screw M4 x 10 black

Spring washer 4 mm

Nut M4

Screw M6 x 8

Screw M4 x 12

Nut M6

Screw M4 x 10

Conductor mark ground cable 1,60

Conductor mark PE-ground cable


51

8 Appendix

8.2 Spare Parts

Spare part list front plate complete IT 3002 (88-17-904)

2

2

7

2

5

Quantity

2

1

1

1

4

12

28

24

19

4

3

1

0.92 m

0.43 m

4

50

52

54

56

58

21

39

41

43

46

60

64

66

68

70

Pos.

1

3

5

12

13

Order No.

88-17-912

88-15-152

88-15-163

88-17-909

88-17-908

80-50-0098

80-10-857

80-10-0633

80-10-0633

80-10-777

80-90-202

80-90-121

80-90-153

80-90-164

80-90-142

80-90-505

80-90-145

80-90-128

80-90-188

80-11-359

Description

Front plate

Inlet air duct

Angle plate

Cover plate

Cover plate

Mounting sleeve

Handle A=300



Cage nut KM6/2,5

Washer 5 mm

Spring washer 4 mm

Nut M4

Washer 4 mm

Screw M4 x 10

Cap nut plastic M4

Screw M5 x 16

Spring washer 5 mm

Nut M5



Front plate complete IT 3002 (88-17-904)

8 Appendix

8.2 Spare Parts


53

8 Appendix

8.2 Spare Parts

Spare part list rear wall complete IT 3002 (88-15-164)

22

24

26

30

32

Pos.

1

3

5

10

20

4

2

1

4

2

Quantity

1

3

2

3

16

Order No.

88-15-165

88-15-145

88-15-166

80-10-777

80-90-319

80-11-359

80-90-142

80-90-121

80-90-296

80-90-147

Description

Rear wall

Fan support complete

Angel plate

Cage nut KM6/2,5

Screw M4 x 8 black


Screw M4 x 10

Spring washer 4 mm

Screw M6 x 12

Spring washer 6 mm


Rear wall complete IT 3002 (88-15-164)

8 Appendix

8.2 Spare Parts


55

8 Appendix

8.2 Spare Parts

Spare part list control unit complete IT 3002 (88-17-903)

6

2

1

12

4

6

3

2

2

3

6

6

4

6

0.39 m

2

8

1

1

3

4

1

3

3

1

1

Quantity

1

1

2

1

1

122

126

128

130

132

134

100

102

108

114

120

84

86

88

92

96

47

69

75

80

82

12

37

38

39

41

Pos.

1

3

5

7

11

80-50-652

80-50-1441

80-50-2641

80-10-842

80-56-215

80-90-147

80-90-146

80-10-851

80-90-319

80-90-195

80-90-296

80-90-128

80-90-127

80-11-359

80-10-0633

80-90-289

Order No.

88-15-186

88-17-406

88-15-188

88-15-189

88-16-691

88-10-546

80-80-557

80-57-332

80-56-041

88-13-164

80-90-288

80-11-499

80-10-777

80-50-640

80-50-693

Description

Baseplate

Operation plate

Rear wall

Distance support

Tie anchor

Cover plate

P.C. board

Resistor

Capacitor

Front film operation plate

Insulating parts

Distance stud M4

Cage nut

Plug

Plug 4 pin

Plug 4 pin

Pole connector

Pole connector

Cable mounting

Capacitor noise suppression

Spring washer 6 mm

Nut M6

Edge protection

Screw M4 x 8 black

Screw M4 x 6

Screw M6 x 12

Spring washer 5 mm

Screw M5 x 8

Conductor mark ground cable


Screw M4 x 12


Control unit complete IT 3002 (88-17-903)

8 Appendix

8.2 Spare Parts


57

8 Appendix

8.2 Spare Parts

Spare part list country module USA complete IT 3002 (88-17-921)

9

3

2

9

1

4

4

4

3

9

2

1

3

12

Quantity

1

1

1

2

1

1

6

6

2

1

41

43

49

51

53

27

29

31

37

39

55

59

80

82

Pos.

13

15

17

23

25

1

3

5

7

11

80-90-164

80-90-121

80-90-110

80-50-0301

80-50-0493

80-50-0458

80-50-0490

80-50-0598

80-50-0492

80-50-0297

80-50-0491

80-50-0489

80-70-429

80-90-163

Order No.

88-16-841

80-90-198

80-90-147

80-90-146

80-50-0709

80-50-0710

80-90-249

80-10-0173

88-17-787

80-80-669

Description

Gun connection

Washer 6 mm

Spring washer 6 mm

Nut M6

External mounting housing

Control cable sleeve

Screw M3 x 6

Clip-on ferrite

Transformer 480 V

P.C. board

Washer 4 mm

Spring washer 4 mm

Screw M4 x 8

Neozed Fuse-base, Gr. D02

Neozed screw cap D02

Neozed fuse 35 A/400 V, Gr. D01

Neozed Screw-in pad socket D02/ 35 A

Neozed Fuse-base, Gr. D01

Neozed screw cap D01

Neozed fuse 4 A/400 V, Gr. D01

Neozed Screw-in pad socket D01/4 A

Neozed bus bar

Power element

Screw M6 x 16


Country module USA complete IT 3002 (88-17-921)

8 Appendix

8.2 Spare Parts


59

8 Appendix

8.3 Circuit Diagram

8.3

Circuit Diagram


8 Appendix

8.4 Environmentally Admissible Disposal

8.4

Environmentally Admissible Disposal

After repair of the power unit, dispose replaced parts in an environmentally admissible way.

Used materials: Steel

-

-

-

Nonferrous metals (brass, copper)

Plastics

Aluminum


61

Glossary

Glossary

Arc:

Automatic welding head:

Capacitor:

Power unit:

Rectifier:

Stud feeder:

Stud welding unit:

Thyristor:

Welding element:

Welding gun:

Welding parameters:

Work piece:

Electrical discharge at its own between two electrodes under sufficiently high current. Whitish light is emitted.

The arc generates very high temperatures.

Device to weld welding elements

A component which serves as storage of electrical charge

Device to provide electrical energy for stud welding

Electric component transforming alternating current into direct current

Device for the automatic stud feeding of welding elements

Power unit inclusive welding gun

Electronic component, contactless switch, which will let the current only pass through if a control pulse is given to the gate (additional electrode)

A component, like a stud, bolt, pin, which is welded to the work piece

Device to weld welding elements

Various settings on the gun as well as on the power unit.

For example: duration and strength of current during welding process, charging voltage, spring force of the welding gun.

A component, like a sheet, tube, etc. to which the welding element is fastened


Regulations and Standards


Description Standards, regulations

Stud welding (fundamentals)

DIN EN ISO 13918

DIN EN ISO 14555

DIN EN 1418

DVS 0901

DVS 0902

DVS 0903

DVS 0904

DVS 2927

Welding - Studs and ceramic ferrules for arc stud welding

Welding - Arc stud welding of metallic materials

Welding personnel - Approval testing of welding operators for fusion welding and resistance weld setters for fully mechanized and automatic welding of metallic materials

Stud welding method for metals - General

Drawn-arc stud welding

Capacitor-discharge stud welding with tip ignition

Instructions for practice - Arc stud welding

Resistor projection welding and Arc welding of one-sided thick plastics coated thin metal sheets

Stud welding (general)

DIN EN ISO 4063

DIN ISO 857-1

DIN EN ISO 14175

DIN EN 764-1

DIN EN ISO 6947

Welding and allied processes - Nomenclature of processes and reference numbers

Welding and allied processes - Vocabulary -

Part 1: Metal welding processes

Welding consumables - Gases and gas mixtures for fusion welding and allied processes

Pressure equipment - Part 1: Terminology -

Pressure, temperature, volume, nominal size

Welds - Working positions - Definitions of angles of slope and rotation


63


Machine safety

2006/95/EC

2004/108/EC

98/37/EC

2006/42/EC

DIN EN 60204-1

DIN EN 60529

DIN EN 60974-1

Electrical equipment designed for use within certain voltage limits

EMC-Guidelines

Machine guideline (valid until 28.12.2009)

Machine guideline (valid from 29.12.2009)

Safety of machinery - Electrical equipment of machines - Part 1: General requirements

Degrees of protection provided by enclosures

(IP code)

Arc welding equipment - Part 1: Welding power sources

DIN EN 60974-10 Arc welding equipment - Part 10:

Electromagnetic compatiblity (EMC) requirements

Personal safety and accident prevention

DIN EN ISO 20345

DIN EN 12477

DIN EN 166

DIN EN 352-1

Personal protective equipment -

Safety footwear

Protective gloves for welders

Personal eye-protection - Specifications

Hearing protectors - General requirements -

Part 1: Ear-Muffs

BGV A1

BGV A3

BGV A8

BGV B11

BGV D1

Accident-prevention regulation „Principles of prevention“

Accident-prevention regulation „Electrical equipment and operating material“

Accident-prevention regulation „Health and safety signs at work“

Safety rules “EMC”

Safety rules - welding, cutting and similar processes

Please note that in your country additional standards and safety conditions (especially rules for accident prevention) may differ from the standards mentioned in this operating manual.


Further Instructions

Further Instructions

Welding elements, abbreviations, materials, standards, mechanical properties to actual standards

Stud types

Abbreviations for studs (ceramic ferrules)

PD (PF)

Material

Mild steel (4.8

1)

)

Norm

ISO 898-1

Mechanical characteristics see ISO 898-1

Stud w elding w ith

draw n arc

(DS)

Draw n arc w elding w ith ceramic ferrule

(CF) or shielding gas

(SG)

Threaded stud

Threaded stud w ith reduced shaft

Pin

Pin w ith internal thread

Head stud

RD (RF)

UD (UF)

ID (UF)

SD (UF)

1.4301/03

(A2-50)

Mild steel

(S235J2G3

+ C450)

1.4301/03

(A2-50)

EN ISO

3506-1 see ISO 3506-1

ISO/TR 15608

EN 10088-1

Rm ≥ 400 N/mm 2

ReH ≥ 235 N/mm

2

A5 ≥ 15%

Rm ≥ 500 - 780 N/mm

2

Rp0,2 ≥ 350 N/mm 2

A5 ≥ 25%

Short cycle w elding w ith draw n arc

Threaded stud w ith flange

Pin w ith flange

Pin w ith internal thread and flange

Further materials on request

PS

US

IS

Mild steel (4.8

1) ) copper plated

1.4301/03

(A2-50)

ISO 898-1

EN ISO

3506-1 see ISO 898-1 see ISO 3506-1

1) weldable

Prestress at installation (tie load) and torque

Threaded stud

M 6

M 8

M 10

M 12

M 16

Steel (4.8

1) )

µ = 0,18

R p0,2

= 340 N/mm 2

Prestress at installation

(kN)

Torque

(Nm)

4,3

8,0

6,1

15,0

13,0

19,0

35,0

30,0

53,0

135,0

1.4301/03 (A2-50)

µ = 0,18

R p0,2

= 210 N/mm 2


(kN)

Torque

(Nm)

2,7

4,9

3,8

9,5

7,8

12,0

22,0

19,0

33,0

82,0

AlMg3 (F23)

µ = 0,18

R p0,2

= 170 N/mm 2


(kN)

Torque

(Nm)

2,2

4,0

3,1

7,5

CuZn37 (Ms63)

µ = 0,18

R p0,2

= 250 N/mm 2


(kN)

Torque

(Nm)

3,2

6,0

4,5

11,0

Values correspond with actual standards

1) weldable

All given values are leads for minimum tensile strength and minimum torque of a weld without permanent deformation of parts to be joined. Parts to be joined must have sufficient wall thickness. Values apply for cold rolled threaded studs with standard thread without surface protection and without thread lubrication. Throughout the entire stud length, at least the stressed cross section must be present. Values apply for indicated yield strengths.

Material combinations

according to the actual standards (select stud material in a way that material of the same kind is welded).

Stud material

ISO/TR 15608

Groups

1 and 2.1

a

Steel (S235) 4.8

1) 16Mo3

1.4301/03, 1.4401/04, 1.4541,1.4571

EN AW-AlMg3/EN AW-5754

EN AW-AlMg5/EN AW-5019 b/a

--

Exemplification of w elding suitability

-- non w eldable a w ell suited for any application, e.g. pow er transmission b suitable, limitations w ith pow er transmission

Base material

ISO/TR 15608

Groups

2.2, 3 to 6 b b

ISO/TR 15608

Groups

8 and 10 b a

- --

ISO/TR 15608

Groups

21 and 22

--

-b

Weldability tests of other material combinations upon request.

1) weldable


65

Guarantee Clauses

Guarantee Clauses

Please refer to the current “General Terms and Conditions” for the guarantee clauses.

We are not liable for malfunctions which are caused by

– normal wear,

– improper use,

– non-observing the operating manual,

– transport damages.

Any guarantee claim will be cancelled if repair operations are carried out by unauthorized persons.


Please fill in the serial number:

Serial number automatic welding head:

Serial number power unit:

Serial number stud feeder:

Serial number welding gun:

..............................................

..............................................

..............................................

..............................................

Please indicate the serial numbers in case of enquiries or when ordering spare parts.


Confirmation

Confirmation

Herewith I confirm that I have read and understand the present operating manual completely.

Date Name

________________

________________

________________

________________

________________

________________

________________

________________

________________

________________

________________

________________

________________

________________

________________

________________

________________

________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________

___________________________________


67

Feedback

Feedback

HBS Bolzenschweiss-Systeme

GmbH & Co. KG

Felix-Wankel-Strasse 18


Postfach 13 46


Sender:

__________________________

__________________________

__________________________

__________________________

__________________________

Product description

Serial number

__________________________

__________________________

My opinion/criticism/complaints/indication of malfunction:

68

Date and signature ___________________________________________


Service & Support

Service & Support


69

Index

70

Index

A

accident prevention ........................12, 23 accident prevention regulations ............ 16 accidents ............................................ 24 accompanying documents ................... 13 airborne particles ................................. 16 allen key ............................................. 45 arc ....................................................... 62 arc blow effect ..................................... 39 arrow keys ........................................... 33 articles, combustible ........................... 16 assembly .............................................. 9 automatic welding head ....................... 62

B

bang ....................................... 17, 24, 35 bending device with inserts .................. 37 bending test ........................................ 37 blow-up ................................................ 23

C

capacitor ............................................. 62 care and maintenance ......................... 10 casing cover ........................................ 46 ceramic ferrule/ring .............................. 27 circuit diagram ..................................... 60 cold formed process ............................ 41 company specific maintenance instruction ................. 9 company specific work order ................. 9 components of the power unit .............. 20 compressed air connection .................. 19 confirmation ......................................... 67 confirmation, operator sign .................... 9 connecting the welding gun ................. 18 control cable connector ....................... 18 corrective actions ................................ 37

D

defective cables ................................... 30 delivery ..........................................10, 15 display ................................................ 21 disposal ............................................... 44 disposal, environmentally admissible ... 61 distance device .................................... 35

DVS regulations .................................. 35

E

ear protection ................................. 9, 23 electrical shock, risk of ....................... 19 electrical voltage ..................... 11, 14, 22 electromagnetic fields ...........................11

entire plug connection, destroying ....... 18

F

fault recognition .............................37, 40 feedback ............................................. 68 fire extinguisher .............................16, 23 fire risk ................................................ 23 flash ....................................... 17, 24, 35 fluids, ingress of .................................. 44 foreign bodies, ingress of ..................... 44 fume extraction .................................... 23 function ............................................... 20 functional principle ............................... 10 further instructions ............................... 65 fuse rating ........................................... 17

G

general .................................................. 9 general safety instructions ................... 12 glossary .............................................. 62 gloves .................................................... 9 ground cable ........................................ 19 ground clamps ..................................... 19 ground conductor ................................. 46 ground connection ............................... 19 guarantee claims .................... 12, 24, 66 guarantee clauses ............................... 66 guide ................................................... 10

H

headgear, protective ............................. 23 heat built-up ........................................ 16 high-strength welds ............................. 30 hollow parts, welding on ...................... 23

I

intended use ........................................ 12

K

keyboard ............................................. 21


Index

L

liability, any ............................ 12, 24, 66 library mode ........................................ 34 liquid spatters ...................................... 35 liquids, combustible ............................. 16 lot ........................................................ 41

M

magnetic fields ..............................16, 24 mains switch ....................................... 32 maintenance ........................................ 45 maintenance instruction for your company ........................... 9 malfunction ..................................... 9, 40 markings ............................................. 14 material combinations ...................32, 65 material separation, environmentally correct ................. 44 metal spatters ..................................... 23

N

non-combustible clothes ...................... 23

O

operating manual ............................ 9, 15 operating manual, storage of ................. 9 operation, improper .............................. 35 operators ............................................... 9 order number .................................15, 48 ordering spare parts ............................. 66

P

pace maker ............................ 11, 17, 24 packaging ............................................ 13 personal injury ......................................11

personnel, properly instructed, qualified ... 9 personnel, qualified ................................ 9 pipes, welding to ................................. 30 place of operation ................................ 12 power unit ......................................20, 62 power unit, switching on ...................... 32 prestress at installation .................32, 65 primary power supply .......................... 17 primary voltage .................................... 17 production ............................................. 9 protective apron ................................... 23 protective equipment ......................17, 24 protective equipment, personal .............. 9 protective gloves .................................. 23 protective goggles .................................. 9 punched plates .................................... 30 punched plates, welding to .................. 30

R

rectifier ................................................ 62 recycling ............................................. 61 regulations ........................................... 63 repair ................................................... 61 requirements of workplace ............. 16, 30 risk of material damage ........................11

room adequately ventilated .................. 23 rooms exposed to risk of explosion ..... 16

S

safety goggles ..................................... 23 safety instructions .................... 9, 22, 45 safety symbols .................................... 14 serial number ...................................... 66 service ................................................... 9 service & support ................................. 69 service technician .................................. 9 set-up .................................................... 9 shoes .................................................... 9 spare part list ...................................... 48 spare parts, ordering of ..................48, 66 special welding elements ..................... 43 standards ............................................ 63 standards, actual ...........................12, 35 starting-up ..................................... 10, 16 storage ................................................ 13 stud feeder .......................................... 62 stud welding, functional principle ......... 25 stud welding procedure ........................ 22 stud welding process ........................... 10 stud welding unit ................................. 62 stud welding, variants .......................... 26 surface of welding element .................. 37 surface, workpiece .............................. 37 switching off, temporary ....................... 44 switching off the power unit ............10, 44

T

technical data ................................10, 47 threat to life ......................................... 10


71

Index

thyristor ............................................... 62 tools .................................................... 45 torque ............................................32, 65 training according to current standards .... 9 transportation ................................. 9, 13 transportation, packaging, storage ....... 13 type plate ......................................14, 17

U

unauthorized use ................................... 9 user qualification, required ..................... 9

V

vapors, toxic ........................................ 16 visual inspection .................................. 36

W

weld, checking the quality of the .......... 36 welding element .................................. 62 welding elements .................... 12, 30, 41 welding elements, lot of ....................... 30 welding gun ...................................12, 62 welding gun cables .............................. 18 welding gun support ............................. 35 welding parameters .......................35, 62 welding parameters, determination ...... 30 welding preparation .............................. 30 welding procedure ................................ 35 welding process .................................. 10 welding spatters .................................. 35 work piece ........................................... 62 working place, change of ..................... 19


HBS Bolzenschweiss-Systeme GmbH & Co. KG • Felix-Wankel-Strasse 18 • 85221 Dachau / Germany

Phone +49 (0) 8131 511-0 • Fax +49 (0) 8131 511-100 • E-mail [email protected]

www.hbs-info.com