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CDM 3201 Power Unit Automatic Version 92-12-3321A Operating Manual...
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+49 (0) 8131 511-100 E-mail post@hbs-info.com www.hbs-info.com CDM 3201 Operating Manual, Issue 09/2008 Order No. BA 92-12-3321A Copyright: The information contained herein may not be copied, reproduced, adapted, merged, translated or used without the prior written consent of the copyright owner.
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For your own sake you should know the safety instructions for operating your HBS stud welding units inside out.
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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. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
Determination of Welding Parameters ............28 Switching on the Power Unit ..............30 5.6.1 Adjusting the Charging Voltage of Capacitors ............32 5.6.2 Setting the Stud Feed Time (Automatic Mode) ............33 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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Open the Power Unit .................. 56 Appendix ..................58 Technical Data .................... 58 Spare Parts ....................59 Transmission of Recognized Data With Microsoft® Hyper Terminal ..74 Environmentally Admissible Disposal ............79 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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Table of Contents Glossary ..................80 Regulations and Standards ............81 Further Instructions ............... 83 Guarantee Clauses ................ 84 Confirmation .................. 85 Feedback ..................86 Service & Support ................. 87 Index ....................88 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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Table of Contents viii CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
(place of operation see section 8.1). The welding guns C 08, CA 08, PAH-1 and the welding head KAH 412 can be connected to the HBS power unit CDM 3201. 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. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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: CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
2 Delivery Delivery The basic equipment of your power unit contains the following components: No. of pieces Part Type Order No. Power unit CDM 3201 92-12-3321A Operating Manual CDM 3201 BA 92-12-3321A CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
Proceed in reversed sequence as described in section 3.2, 3.3, 3.4 and 3.5. After changing the workplace, check the welding gun and the ground cables for possible damage or missing components. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
The charging process as well as the welding process are controlled by the control unit (2). The negative pole of the capacitor is connected to the welding gun. The positive pole is mostly connected to the work piece via the vice grips. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
You can program the power unit with the keys according to your requirements. How to use displays and keys is described in section 5.6. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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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. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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HBS. In case of any accidents whatsoever, advise a physician, your supervisor, and the official bodies immediately. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
– The use of contact welding for rapidly oxidizing materials like aluminum and aluminum alloys is not recommended because the arcing period with contact welding is longer than with gap stud welding. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
With high plunging speed of the welding element, the air gap closes after vaporization of the ignition tip faster, thus the arc time becomes shorter. With rapidly oxidizing materials like e.g. aluminum, the arc must only burn a very short time. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
– material of the workpiece The guidelines should be verified by test welding on the actual material and be changed if necessary. For an assessment of welding results, see section 5.8 and 5.9. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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Further notes on – welding elements – prestress at installation (tie load) and torque – material combinations see appendix and operating manual of the according welding gun. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
– Unit temperature – Thyristor malfunction If one of the above mentionned parameters deviates fron the nominal value, an error message is displayed on the operator terminal, see section fault recognition and corrective actions. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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2 x 20 characters, height 9 mm, with background illumination and automatic contrast control Keys ENTER, confirmation of selected function ARROW, marks the selected program item PLUS, increases the selected parameter MINUS, decreases the selected parameter CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
Refer to the table in section 5.5 for the required charging voltage matching your welding job. Select the menu item charging voltage with the arrow key Set the charging voltage (LCD display) with the two arrow keys ) on the display. >150 V CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
Press the arrow key until >150 V the sign ">" appears to the left of "xxx V". ⇒ increase charging voltage with ⇒ decrease charging voltage with Charging voltage: 50 V to 220 V CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
M5 AlMg3 >130 V the sign ">" appears to the left of "xxx V". ⇒ increase charging voltage with ⇒ decrease charging voltage with Charging voltage: 50 V to 220 V CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
In this way, the PAF value can be stored for different program sequences. It is possible to store an individual PAF value for each stud/lot dimension and to carry out a process monitoring. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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Welds for determination of the PAF value and/or manual entry of the PAF value Reference determination (sequence 1): Reference entry (sequence 2): > Control ON >Control ON Ref. welding Ref. Input At first you must select a welding program in the program mode. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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Control ON Range( ) > Here you define the tolerance range. - increase tolerance range - decrease tolerance range small tolerance range high sensitivity 20 - large tolerance range low sensitivity CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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The settings of the power unit must be checked in the following cases: change of base material, lot of welding elements, set- tings of the welding gun. The PAF value must be redetermined in the case of changed conditions. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
Now you can work as with standard welding sequence, you can adjust a lift at the welding gun greater than zero, position the welding gun onto the work piece and trigger it. ⇒ The welding gun lifts off. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
">" appears in front of "Reset". Service >Reset ⇒ with the enter key open the menu item "Reset" RESET ⇒ with the enter key confirm"Reset" ⇒ with the arrow key cancel "Reset". CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
"Thyristor 1 + 2“ > Thyristor 1 + 2 With "Thyristor 1“ you select 800 Ws, with "Thyristor 1 + 2“ 2400 Ws are available. 5.6.10 Adjusting the Gas Pre-Flow Time Option CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
You can now insert a new welding element in the chuck and repeat the welding process as described above. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
The power unit controls the air between these two sleeves. With false connections, feeding and welding problems may occur. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
A welding start can also be effected via the welding gun control plug at the front of the power unit (Pin 3; 4). For a welding start short-circuit Pin 3; 4 for at least 100 ms. Power unit CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
Via the serial interface of the power unit, the actually recorded data can be output for a potential storage in ASCII format. A data cable is required which can be ordered as a consumable at HBS (order no. 80-70-308). Example for data output at serial output (e.g. Microsoft® Hyper Terminal) Output serial interface CDM units Prg./...
- Take care for symmetrical ground One-sided spatter collar - Unsymmetric ground connection connection Weld pool came out on one side - Welding gun put at an angle - Put welding gun vertically to the workpiece CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
(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. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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- Pressure too high - Reduce pressure - Contact stud welding - Use gap stud welding instead of not suitable contact stud welding - Workpiece too thin - Adapt thickness of workpiece CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
(applies for welding guns with external welding cable). Arc blow effects and some corrective actions (according to standards, see appendix) Cause Corrective action CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
(18 Ω to 22 ) between Pin 1 and Pin 2 *) Actions marked with *) must only be carried out by qualified electricians! If none of the actions is successful, please contact our service department. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
Switch off the unit, switch on after approx. 5 minutes, if error is still present, contact HBS service Key sticks Key of operating terminal sticks Trigger several times, if error is still present, contact HBS service Battery voltage Voltage buffer battery main board too low Switch off the unit, switch on after approx.
10-40 mm 82-50-908 Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303 / CuZn37 / AlMg3 * from 40 mm length upwards only weldable with distance ring up to 55 mm, order no. 92-40-010. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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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 ** from 100 mm length only weldable with tripod, order no. 92-40-043. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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.
50 V for 5 minutes, then to 75 V, 100 V, 125 V... for 5 minutes each. Tools to be Used – Cross-slotted screwdriver, size 2 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
Remove the 14 screws of the casing (5 at each side and 4 on top). Carefully remove the cover and disconnect the ground cable on the inside of the cover. Now pull off the cover. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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Measure the voltage with a commonly used voltmeter (Measurement range direct current DC/–). The displayed voltage must be below 10 V. Re-assemble the power unit in reverse sequence. Make sure that no cables are jammed or sheared during assembly. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
In the appendix, there is information of interest regarding technical data, spare part lists, accessories, standards, etc. Technical Data Power Unit CDM 3201 (with wide range power supply) for CD stud welding (capacitor discharge welding) according to current standards Welding range #4 to 7/16”, dia.
8 Appendix 8.2 Spare Parts Spare Parts Spare part list power unit type CDM 3201 (92-12-3321A) When ordering spare parts, please indicate order number and type of power unit Pos. Quantity Order No. Description 88-14-079 Bottom plate complete 80-30-230 Capacitor battery 1...
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8 Appendix 8.2 Spare Parts Power unit type CDM 3201 (92-12-3321A) CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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8 Appendix 8.2 Spare Parts Spare part list capacitor battery 1 CDM 3201 (80-30-230) Pos. Quantity Order No. Description 88-10-112 Capacitor support 80-10-851 Edge protection 80-56-133 Capacitor 80-11-116 Grommets support 80-90-191 Screw M4 x 8 80-90-121 Spring washer 4 mm...
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8 Appendix 8.2 Spare Parts Capacitor battery 1 CDM 3201 (80-30-230) CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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8 Appendix 8.2 Spare Parts Spare part list capacitor battery 2 CDM 3201 (80-30-232) Pos. Quantity Order No. Description 88-10-112 Capacitor support 80-10-851 Edge protection 80-56-133 Capacitor 80-11-116 Grommets support 80-90-191 Screw M4 x 8 80-90-121 Spring washer 4 mm...
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8 Appendix 8.2 Spare Parts Capacitor battery 2 CDM 3201 (80-30-232) CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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8 Appendix 8.2 Spare Parts Spare part list control insert complete CDM 3201 (80-30-270) Pos. Quantity Order No. Description 88-10-117 Control casing 80-10-280 Distance stud 80-80-428 P.C. board 80-90-190 Spring washer 3 mm 80-90-137 Screw M3 x 8 80-90-263 Nut M3...
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8 Appendix 8.2 Spare Parts Control insert complete CDM 3201 (80-30-270) CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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8 Appendix 8.2 Spare Parts Spare part list adaptive control module CDM 3201 (92-50-029) Pos. Quantity Order No. Description 88-10-110 Valve carrier 80-90-191 Screw M4 x 8 80-90-121 Spring washer 4 mm 80-10-188 Solenoid valve 80-10-189 Utensil socket 1.1 m...
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8 Appendix 8.2 Spare Parts Adaptive control module CDM 3201 (92-50-029) CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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8 Appendix 8.2 Spare Parts Spare part list terminal plate complete CDM 3201 (88-13-881) Pos. Quantity Order No. Description 88-10-104 Terminal plate 80-50-035 Mounting sleeve 80-30-193 Control cable sleeve 80-11-440 Cable screwing 80-11-441 Lock nut 80-10-576 Flat connection 80-56-215 Capacitor noise suppression...
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8 Appendix 8.2 Spare Parts Terminal plate complete CDM 3201 (88-13-881) CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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8 Appendix 8.2 Spare Parts Spare part list module bottom plate complete CDM 3201 (88-14-079) Pos. Quantity Order No. Description 88-10-123 Bottom plate 80-10-203 Support legs 80-08-832 Resistor support 80-50-775 Mains interference filter 80-57-037 Resistor 30R, 70W 88-10-106 Rear wall...
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8 Appendix 8.2 Spare Parts Module bottom plate complete CDM 3201 (88-14-079) CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
Switch on the controlling function of the output voltage (see section 5.6.4). 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/Laptop.
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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 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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8 Appendix 8.3 Transmission of Recognized Data With Microsoft® Hyper Terminal Define the connection settings Transmission rate: (Bits per second) – CDM units 19200 – IT 1000 units 115200 Confirm with OK CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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8 Appendix 8.3 Transmission of Recognized Data With Microsoft® Hyper Terminal Do not forget to save data CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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8 Appendix 8.3 Transmission of Recognized Data With Microsoft® Hyper Terminal Give a file name Confirm with start CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
8 Appendix 8.4 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 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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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. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
-- non weldable a well suited fo r any applicatio n, e.g. po wer transmissio n b suitable, limitatio ns with po wer transmissio n Weldability tests of other material combinations upon request. weldable CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
Serial number automatic welding head: ..........Serial number power unit: ..........Serial number welding gun: ..........Serial number stud feeder: ..........Please indicate the serial numbers in case of enquiries or when ordering spare parts. CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
__________________________ 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 ____________________________________________ CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
......... 27 contact ........22, 31, 45 gas pre-flow time ......... 41 contact welding ........26 general ..........9 control cable connector ....... 18 general safety instructions ....12 control sleeve ........44 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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......9 protective gloves ........24 maintenance instruction protective goggles ........9 for your company ......9 PT, threaded stud ....29, 52, 83 malfunction ..........9 punched plates, welding to ....28 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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......42 stud welding procedure ......23 welding head ........43 stud welding process ......10 welding parameters ....... 42, 80 stud welding unit ......... 80 welding parameters, determination of ..28 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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......28 welding procedure ........ 42 welding process ........10 welding spatters ........42 welding thyristor ........21 welds, high-strength ......28 work piece ........... 80 working place, change of ..... 20 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08...
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