Page 1
IT 1002 Power Unit CP Version 93-66-1206 Operating Manual...
Page 2
+49 (0) 8131 511-100 E-mail post@hbs-info.com www.hbs-info.com IT 1002 Operating Manual, Issue 11/2008 Order No. BA 93-66-1206 Copyright: The information contained herein may not be copied, reproduced, adapted, merged, translated or used without the prior written consent of the copyright owner.
Page 3
For your own sake you should know the safety instructions for operating your HBS stud welding units inside out.
Page 4
If you should detect errors or mistakes right in this manual, please contact us: HBS Bolzenschweiss-Systeme GmbH & Co. KG Felix-Wankel-Strasse 18 85221 Dachau / Germany A feedback blank is provided in the appendix. IT 1002 Order No. BA 93-66-1206 Issue 03.11.08...
Drawn-Arc Stud Welding with Shielding Gas ............30 5.2.3 Short-Cycle Drawn-Arc Stud Welding with Shielding Gas ........31 5.2.4 Drawn-Arc Capacitor-Discharge Stud Welding ............31 Welding Preparation ................... 32 High-strength Welds ................... 32 IT 1002 Order No. BA 93-66-1206 Issue 03.11.08...
Page 6
Open the Power Unit .................. 58 Appendix ..................59 Technical Data .................... 59 Spare Parts ....................60 Circuit Diagram ..................74 Transmission of Recognized Data With Microsoft® Hyper Terminal ..75 Environmentally Admissible Disposal ............80 IT 1002 Order No. BA 93-66-1206 Issue 03.11.08...
Page 7
Table of Contents Glossary ..................81 Regulations and Standards ............82 Further Instructions ............... 84 Guarantee Clauses ................ 85 Confirmation .................. 86 Feedback ..................87 Service & Support ................. 88 Index ....................89 IT 1002 Order No. BA 93-66-1206 Issue 03.11.08...
Page 8
Table of Contents viii IT 1002 Order No. BA 93-66-1206 Issue 03.11.08...
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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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 IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
The welding guns A 12, A 16, AI 06, CA 08, PAH-1 and the welding head KAH 412 can be connected to the HBS power unit IT 1002. For details please contact the HBS customer service (address see page ii).
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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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: IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
2 Delivery Delivery The basic equipment of your power unit contains the following components: No. of pieces Part Type Order No. Power unit IT 1002 93-66-1206 Operating Manual IT 1002 BA 93-66-1206 IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Ensure that air is able to circulate freely through the housing. If heat is built-up inside the housing caused by bad air circulati- on, the stud welding unit will be seriously damaged. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Connect the ground clamps to the workpiece as securely as possible. Take care to ensure good contact and symmetrical connection. The welding location must lie directly between the two ground clamps. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Set the flow meter of the shielding gas bottle to 8 - 16 liters/min. Minimum flow rate for stud welding with shielded gas is 8 l/min. A gas mixture of 82% Argon (Ar) and 18% carbon dioxide (CO ) is mainly used for stud welding. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Proceed in reversed sequence as described in sections 3.2, 3.3, 3.4, 3.5 and 3.6. After changing the workplace, check the welding gun and the ground cables for possible damage or missing components. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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). IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
(ignition of pilot arc, ignition of main arc, sequence of welding time). The welding time is stepless adjustable. Keyboard and Display How to use displays and keys is described in section 5.6. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 25
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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 26
HBS. In case of any accidents whatsoever, advise a physician, your supervisor, and the official bodies immediately. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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’...
Page 28
[ms] = 20 x d (up to 12 mm/0,47") (up to 12 mm/0,47") Lift Lift Lift Spring pressure (arc length) (arc length) (arc length) (plunging speed) Plunging depth Plunging depth Plunging depth Plunging depth IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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 are preferably used with ceramic ferrule. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Studs with cone-shaped front area preferably used under shielding gas. With shielding gas, you should only weld in position PA (verti- cal) because due to gravity, the shielding gas cannot prevent flow of the molten metal. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
DVS guidelines (see appendix). Before you use another lot of welding elements, carry out some trial welds to verify the parameter setting. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 33
Welding energy is only selected by welding time. Further notes on – welding elements – prestress at installation (tie load) and torque – material combinations see appendix and operating manual of the according welding gun. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 35
Green – lights, automatic mode is switched on Green – lights, shielding gas is switched on The LCD display shows the last set values. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
. To confirm settings and to quit a menu item is also carried out via the enter 5.6.1 Adjusting the Welding Time Set the welding time (digital display ) with the arrow keys (⇑ longer – ⇓ shorter) on the display. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
You don’t need any special welding guns and/or additional welding cables for this system of function monitoring. During welding the reference, the micro controller determines a reference output voltage value. This is the average value of eight consecutive weldings. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 39
= high sensitivity large tolerance range = low sensitivity Press the enter key , the following menu is displayed: REFERENCE MODE REFERENCE MODE STOP: OFF STOP: ON You change the menu boxes with IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 40
. U-REF 25.00V means that you define the set reference value 25V for program place 1. Press the enter key , the following menu is displayed: PROGRAM 1 TOLERANCE: 10% Here you define the tolerance range. Increase tolerance range Decrease tolerance range IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 41
Press the arrow key until the menu ‘Date’ is displayed. ADJUSTING DATE 06.07.05 With , you can enter the individual digits. You change the position with the arrow key Confirm with the enter key IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 42
, you can enter the individual digits. You change the position with the arrow key Confirm with the enter key Adjusting the Language Press the arrow key until the menu ‘Language’ is displayed. SELECTION LANGUAGE ENGLISH With , you can enter the individual language. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
You can now insert a new welding element in the chuck and repeat the welding process as described above. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
The power unit controls the air between these two bushes. If the conduits are wrongly connected, feeding and welding malfunctions will occur. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
A welding start can also be provided with the welding gun control plug at the front side of the power unit (pin 3; 4). To start welding, you must short- circuiting pin 3 and 4 for at least 100 ms. Power unit IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
(control socket 3 poles, pin 1; 3). Operating voltage 24 V DC Current capacity max. 50 mA Operating the automatic welding head KAH 412 (see operating manual). IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Via the serial interface of the power unit, current monitoring data can be output in ASCII format for a possible record. A data cable is required which you can order at HBS as an accessory (order no. 80-70-308). Example for data output at the serial output (e.g. Microsoft® Hyper Terminal)
Weld collar low , shiny surface w ith many - Welding energy too high - Decrease current and/or time spatters Welding element too short - Plunging speed too high - Adjust plunging depth and/or damping factor IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
5.8 Checking the Quality of the Weld 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.
Page 50
- Increase plunging speed - Unsuitable stud/base - Replace welding element or material combination workpiece Fracture in the weld metal - Welding time too short - Increase welding time Shiny fracture surface IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
(applies for welding guns with external welding cable). Arc blow effects and some corrective actions (according to standards, see appendix) Cause Corrective action IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Check shielding gas valve *) Replace shielding gas valve *) 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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
20-50 mm 83-50-008 83-51-008 20-160 mm 83-50-010 83-51-010 25-160 mm 83-50-012 83-51-012 30-160 mm 83-50-016 Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303 * Please use only welding elements without aluminum ball. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 54
Ceramic ferrule RF Diameter Ceramic ferrule support for threaded stud RD 80-31-095 80-31-120 80-31-150 80-31-170 80-31-205 Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303 * Please use only welding elements without aluminum ball. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 55
We look forward to consult you with view to special welding elements and other special materials. HBS Bolzenschweiss-Systeme GmbH & Co. KG Felix-Wankel-Strasse 18 85221 Dachau / Germany Phone +49 (0) 8131 511-0 +49 (0) 8131 511-100 E-mail post@hbs-info.com IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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.
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 – Cross-slotted screwdriver, size 2 IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Carefully remove the cover and disconnect the ground cable on the inside of the cover. Now pull off the cover. Re-assemble the power unit in reverse sequence. Make sure that no cables are jammed or sheared during assembly. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Operational and storage conditions According to current standards Dimension L x W x H 25.98” x 11.02” x 13.39” (660 x 280 x 340 mm) without handle Weight 63.93 lbs (29 kg) IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
8 Appendix 8.2 Spare Parts Spare Parts Spare part list power unit type IT 1002 (93-66-1206) When ordering spare parts, please indicate order number and type of power unit. Pos. Quantity Order No. Description 88-17-929 Power element complete 88-18-013 Terminal plate complete...
Page 61
8 Appendix 8.2 Spare Parts Power unit IT type 1001 (93-66-1206) IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 62
8 Appendix 8.2 Spare Parts Spare part list front plate complete IT 1002 (88-13-159) Pos. Quantity Order No. Description 88-13-160 Operation plate 88-13-161 Front film operation plate 80-80-558 P.C. board 80-70-325 Connection cable 80-80-559 P.C. board 80-11-987 Distance sleeve 80-10-0174...
Page 63
8 Appendix 8.2 Spare Parts Front plate complete IT 1002 (88-13-159) IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 64
8 Appendix 8.2 Spare Parts Spare part list supply module complete IT 1002 (88-17-997) Pos. Quantity Order No. Description 88-14-166 Support angular plate 88-13-178 Clamp angle 88-14-167 Cable channel 88-14-168 Angle 88-16-406 Transformer 80-80-597 P.C. board 80-50-927 Mains interference filter 80-80-557 P.C.
Page 65
8 Appendix 8.2 Spare Parts Supply module complete IT 1002 (88-17-997) IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 66
8 Appendix 8.2 Spare Parts Spare part list shielding gas module IT 1002 (88-13-167) Pos. Quantity Order No. Description 80-10-145 Connector female 80-10-0916 Swivel connection 80-10-167 Screwing 80-10-240 Connector male 80-10-146 Solenoid valve 80-10-1073 Lock nut G1/4” 80-10-143 Connector female 0.26 m...
Page 67
8 Appendix 8.2 Spare Parts Shielding gas module IT 1002 (88-13-167) IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 68
8 Appendix 8.2 Spare Parts Spare part list terminal plate complete IT 1002 (88-18-013) Pos. Quantity Order No. Description 88-18-014 Terminal plate 80-50-035 Mounting sleeve 80-10-0960 Screwed cable connection 80-11-567 Lock nut M25 x 1,5 80-50-480 Mains switch 80-10-0173 Clip-on ferrite...
Page 69
8 Appendix 8.2 Spare Parts Terminal plate complete IT 1002 (88-18-013) IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 70
8 Appendix 8.2 Spare Parts Spare part list module adapter control IT 1002 (88-14-157) Pos. Quantity Order No. Description 88-10-110 Valve carrier 80-10-188 Solenoid valve 80-10-189 Utensil socket 1.4 m 80-10-182 Plastic hose 80-10-024 Nipple 80-10-139 Connector male 80-10-143 Connector female...
Page 71
8 Appendix 8.2 Spare Parts Module adapter control IT 1002 (88-14-157) IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 72
8 Appendix 8.2 Spare Parts Spare part list power element complete IT 1002 (88-17-929) Pos. Quantity Order No. Description 88-14-158 Bottom plate 88-13-170 Rear wall 88-14-159 Screen angle plate 88-14-160 Intake channel 80-70-429 Power unit 80-10-203 Casing feet 80-11-111 Cage nut M4...
Page 73
8 Appendix 8.2 Spare Parts Power element complete IT 1002 (88-17-929) IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Switch on the controlling function of the output voltage (see section 5.6.7). Any data can individually be processed in the window Microsoft® Hyper Terminal. Link the data cable (HBS Order no. 80-70-308) to the serial sleeve of the power unit and to the serial sleeve (com1 or com2) of a PC’s/Laptop.
Page 76
Name the connection (e.g. the company name or a date - however without dots) Select a symbol (any symbol) Confirm with OK Define the interface (com1 or com2 at the PC) Confirm with OK IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 77
8 Appendix 8.4 Transmission of Recognized Data With Microsoft® Hyper Terminal Define the connection settings Transmission rate: (Bits per second) – CDM units 19200 – IT 1002 units 115200 Confirm with OK IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 78
8 Appendix 8.4 Transmission of Recognized Data With Microsoft® Hyper Terminal Do not forget to save data IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 79
8 Appendix 8.4 Transmission of Recognized Data With Microsoft® Hyper Terminal Give a file name Confirm with start IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
8 Appendix 8.5 Environmentally Admissible Disposal 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 IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
For example: duration and strength of current during welding process, charging voltage, spring force of the welding gun. Work piece: A component, like a sheet, tube, etc. to which the welding element is fastened IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
DIN EN 764-1 Pressure equipment - Part 1: Terminology - Pressure, temperature, volume, nominal width DIN EN 6947 Welds - Working positions - Definitions of angles of slope and rotation DIN 1910 Welding IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 83
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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
-- non w eldable a w ell suited for any application, e.g. pow er transmission b suitable, limitations w ith pow er transmission Weldability tests of other material combinations upon request. weldable IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
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. IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
__________________________ Felix-Wankel-Strasse 18 __________________________ 85221 Dachau / Germany __________________________ Postfach 13 46 __________________________ 85203 Dachau / Germany __________________________ Product description __________________________ Serial number __________________________ My opinion/criticism/complaints/indication of malfunction: Date and signature ___________________________________________ IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
........19, 58 control cable connector ....... 18 ground clamps ........19 cooling fan ........... 59 ground connection ....... 19 corrective actions ........ 49 guarantee claims ....12, 26, 85 IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 90
...... 25 safety goggles ........25 safety instructions ....9, 24, 57 safety symbols ........14 OK/ERR ..........47 SELECT LANGUAGE ......36 operating manual ......9, 15 serial number ........85 IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 91
..9 transmission rate ......... 77 transportation ......... 9, 13 transportation, packaging, storage ..13 type plate ........14, 17 unauthorized use ........9 user qualification, required ..... 9 IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Page 92
IT 1002 Order No BA 93-66-1206 Issue 03.11.08...
Need help?
Do you have a question about the IT 1002 and is the answer not in the manual?
Questions and answers