HBS C 08 Operating Manual
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HBS C 08 Operating Manual

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C 08
Welding Gun
92-20-262
Operating Manual

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  • Page 1 C 08 Welding Gun 92-20-262 Operating Manual...
  • Page 2 +49 (0) 8131 511-100 E-mail post@hbs-info.com www.hbs-info.com C 08 Operating Manual, Issue 03/2008 Order No. BA 92-20-262 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. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 5: Table Of Contents

    Safety Instructions ..................22 Functional Principle of Stud Welding ............25 5.2.1 Contact Stud Welding .................... 25 Welding Preparation ................... 26 High-strength Welds................... 26 Determination of Welding Parameters ............26 Welding Procedure ..................28 C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 6 Environmentally Admissible Disposal ............48 Glossary ..................49 Regulations and Standards ............50 Further Instructions ............... 52 Guarantee Clauses ................ 53 Confirmation .................. 54 Feedback ..................55 Service & Support ................. 56 Index ....................57 C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 7: General

    Owners and operators make sure that the welding gun 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. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 8: Guide To This Operating Manual

    All instructions contained in this manual must also be obser- ved by qualified operators. The welding process and the sequence of procedures to carry out a weld are described in chapter 5. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 9: Safety Symbols

    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 C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 10: General Safety Instructions

    (place of operation see section 8.1). The welding gun C 08 can be connected to the HBS power units CD 1501, CD 2301, CD 3101, CDM 1601, CDM 2401 and CDM 3201. For details please contact the HBS customer service (address see page ii).

  • Page 11: Transportation, Packaging, Storage

    Accompanying Documents In addition to this operating manual, you must observe the operating manual of the power unit as well as applicable accident prevention and safety instructions. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 12: Markings

    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: C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 13: Delivery

    The basic equipment of your welding gun contains the following components: No. of pieces Part Type Order No. Gun cable length 6.5 m C 08 92-20-262 Operating manual C 08 BA 92-20-262 C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 14: Starting-Up

    – 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. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 15: Connecting The Welding Gun To The Power Unit

    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. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 16: Ground Connection

    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. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 17: Change Working Place

    Proceed in reversed sequence as described in section 3.2 and 3.3. After changing the workplace, check the welding gun and the ground cables for possible damage or missing components. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 18: Function

    At the front of the welding gun handle, the welding gun trigger (6) is installed. It is used to trigger the welding process. The serial number (7) can be found on the welding gun handle. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 19: Adjustment Of Chuck

    Adjust the standard stop pin in such a way that an overall distance of 50 mm is obtained between upper face of the retaining nut and bottom of the welding element. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 20: Installation Of Chuck

    Installation of Chuck Put the chuck with loose retaining nut up to the stop into the piston of the welding gun. Tighten the retaining nut with the socket wrench SW 17. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 21: Adjustment Of Spring Force

    Turning the adjustment piece spring force clockwise decreases the spring pre-tensioning of the welding piston. Turning the adjustment piece spring force anti-clockwise increases the spring pre-tensioning of the welding piston. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 22: Stud Welding Procedure

    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. C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 23 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. C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 24 HBS. In case of any accidents whatsoever, advise a physician, your supervisor, and the official bodies immediately. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 25: Functional Principle Of Stud Welding

    – 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. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 26: Welding Preparation

    – 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 5.7 and 5.8. C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 27 5 Stud Welding Procedure 5.5 Determination of Welding Parameters Example: welding parameters for welding gun C 08 in connection with power unit CD 1501 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 appendix).

  • Page 28: Welding Procedure

    You can now insert a new welding element in the chuck and repeat the welding process as described above. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 29: Checking The Quality Of The Weld

    - 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 C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 30: Bending Test

    5.7 Checking the Quality of the Weld 5.7.2 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 31 - 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 C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 32: Arc Blow Effect

    (applies for welding guns with external welding cable). Arc blow effects and some corrective actions (according to standards, see appendix) Cause Corre ctive action C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 33: Malfunctions And Corrective Actions

    Actions marked with *) must only be carried out by qualified electricians! If none of the actions is successful, please contact our service department. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 34: Welding Elements

    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. C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 35 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 ** above 100 mm length, only weldable with tripod order no. 92-40-043. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 36: Switching Off The Welding Gun

    Protect the welding gun against ingress of fluids and foreign bodies. Disposal If you shut down the installation, you can return the complete welding gun to HBS (for address see page ii). We will take care of environmentally correct material separation and disposal.

  • Page 37: Care And Maintenance

    Before you start any cleaning and maintenance operation with welding gun, switch off the connected power unit and disconnect control cable and welding cable from power unit. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 38: Regular Maintenance Operations

    This may significantly affect life expectancy of your welding gun. There are some markings (type and adjustment guides) placed at the welding gun. Take care that markings remain clearly visible. Replace illegible or damaged markings. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 39: Appendix

    Operational and storage conditions According to current standards Dimension L x W x H 6.70" x 1.57" x 5.51" (170 x 40 x 140 mm) (without cable) Weight 1.10 lbs (0.5 kg) (without cable) C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 40: Spare Parts

    8 Appendix 8.2 Spare Parts Spare Parts Spare part list welding gun type C 08 (92-20-262) When ordering spare parts, please indicate order number and type of welding gun. Pos. Quantity Order No. Description 88-10-673B Basic shell, complete 80-09-045 Cover shell...
  • Page 41 8 Appendix 8.2 Spare Parts Welding gun type C 08 (92-20-262) C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 42: Accessories

    Ø 4 mm 82-50-004 Ø 5 mm 82-50-005 Ø 6 mm 82-50-006 Ø 7.1 mm 82-50-071 Bushes with internal thread IT Ø 5 mm 82-50-905 Ø 6 mm 82-50-906 Ø 7,1 mm 82-50-971 C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 43 Flat pin + 6.3 mm 82-50-050 Double flat pin Chuck ISO-nail Ø 2 mm 82-50-020 Ø 3 mm 82-50-030 Welding of welding Angle PWA 82-40-011 elements up to 8.5 mm minimum distance C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 44 100 to 300 mm length 92-40-043 welding elements from 40 mm length PSI2 3-point foot piece 80-40-127 PSI2 Foot 80-40-306 PSI2 Clamping plate 80-40-126 PSI2 Tripod pillar 70 mm length 80-40-129 220 mm length 80-40-130 C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 45 Ø 30 mm 80-40-083 PZV2 Centering pot (to adjust) Ø 20 mm 80-40-092 Ø 26 mm 80-40-096 Ø 30 mm 80-40-093 PZV2 Pin 10 x 70 (to adjust) 80-10-092 PZV2 Chuck extension 80-40-081 C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 46 40 to 56 mm length Foot ring Foot Ø 6 mm 80-40-049 Ø 6 mm with hard tip 80-40-076 Pitch circle Ø Foot ring TK38 80-40-521 diameter 38 mm TK38 Foot 80-40-077 C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 47 M3 80-40-121 for welding elements M4 80-40-122 for welding elements M5 80-40-123 for welding elements M6 80-40-124 for welding elements M8 80-40-125 Center punching Automated punch ATK 80-10-353 (Constant punch size) C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 48: Environmentally Admissible Disposal

    8 Appendix 8.4 Environmentally Admissible Disposal Environmentally Admissible Disposal After repair of the welding gun, dispose replaced parts in an environmentally admissible way. Used materials: Steel Nonferrous metals (brass, copper) Plastics Aluminum C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 49: Glossary

    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 C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 50: Regulations And Standards

    DIN EN 764-1 Pressure equipment - Part 1: Terminology - Pressure, temperature, volume, nominal size DIN EN ISO 6947 Welds - Working positions - Definitions of angles of slope and rotation C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 51 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. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 52: Further Instructions

    -- non weldable a well suited fo r any applicatio n, e.g. po wer transmission b suitable, limitatio ns with power transmissio n Weldability tests of other material combinations upon request. weldable C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 53: Guarantee Clauses

    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. C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 54: Confirmation

    ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 55: Feedback

    __________________________ 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 ___________________________________________ C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 56: Service & Support

    Service & Support Service & Support C 08 Order No. BA 92-20-262 Issue 01.03.08...

  • Page 57: Index

    ......25 control cable connector ....... 16 headgear, protective ......23 heat built-up ........14 delivery ........... 8, 13 hollow parts, welding on ...... 23 disposal ......... 36, 48 distance device ........28 C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 58 ......... 26 pin with internal thread IT ..... 34 spring force adjustment ....18, 21 pipes, welding to ......... 26 standards ..........50 place of operation ........ 10 standards, actual ......10, 28 C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 59 ........10, 49 welding gun cables ......16 welding gun support ......28 welding gun trigger ......18 welding overhead ......... 23 welding parameters ....... 28, 49 welding parameters, determination of ... 26 C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 60 C 08 Order No. BA 92-20-262 Issue 01.03.08...
  • Page 62 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 post@hbs-info.com www.hbs-info.com...

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Ba 92-20-262

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