HBS Visar 650 Operating Manual

Stud welding unit

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Visar 650

Stud Welding Unit

93-60-0650

Operating Manual

©HBS Bolzenschweiss-Systeme GmbH & Co. KG

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Page 1 Visar 650 Stud Welding Unit 93-60-0650 Operating Manual ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 2 +49 8131 511-100 E-mail international@hbs-info.com www.hbs-info.com Visar 650 Operating Manual Issue 2021-01 Order No. E-BA 93-60-0650 Translation of the Original Operating Manual Please keep the manual in a safe place for future reference. Transmission and duplication of this document, dissemination and notification of the contents are not permitted unless expressly approved.
Page 3 Dear Customer, Many thanks for buying a stud welding machine from HBS Bolzenschweiss-Syste- We at HBS wish you success at all times when working with this stud welding ma- chine. The high level of quality of our products is guaranteed by ongoing further deve- lopment in the design, equipment and accessories.
Page 4: Table Of Contents
Connecting the Ground Cable ................31 11.3 Connecting the Stud Welding Unit to the Mains Supply ........33 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 5 Disposal ....................53 EC Declaration of Conformity ................54 Service & Support ....................55 Index ........................56 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 6: Important Safety Precautions
You will otherwise endanger yourself. This can lead to serious injury or ex- tensive material damage. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 7 ‹ Observe furthermore your working instructions and the accident prevention regulations. This will help to avoid health damage due to fumes and airborne parti- culates. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 8 This will help to prolong the service life of your stud welding machine. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 9 To reduce the danger posed by electromagnetic fields, we recommend, among other things, the following rules of conduct: ‹ Lay all cables as close together as possible. For proper bundling and safeguarding of the cables, HBS offers protective tubes in various sizes. ‹ Do not position yourself between the welding cables.
Page 10: Symbols And Terms Used
This symbol prompts you to wear ear protection. A loud bang > 90 dB (A) can occur during the welding process. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 11 Have a suitable fire extinguisher for the working area ready before starting work. Work instruction – List ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 12 Workpiece: Components such as sheet metal or tubes to which the welding elements are to be fastened ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 13: Scope Of Supply
The following accessories are available: No. of pieces Part Type Order No. Ground cable 5 m, 25 mm² 93-40-020 Toolbag 88-24-466 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 14 *) recommended welding range Visar 650 / welding gun with this equipment ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 15: Technical Data
5 Technical Data Technical Data Stud welding unit Visar 650 for ARC stud welding according to current standards Welding range ARC: dia. 2 to 8 mm, M3 to M10 (type RD) dia. 2 to 6 mm, M3 to M6 Welding material...
Page 16: Intended Use
Any other use will result in the desired strength of the welded joint being reduced. This stud welding unit can only be used with the HBS stud welding guns A 12 and A 12-FL. The intended use also implies observance of the stud welding gun operating manual and compliance with the intervals and conditions for inspection and maintenance of the stud welding unit and the components employed.
Page 17: Warranty
The same applies likewise to installed units from our sub- suppliers. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 18: Components Of The Stud Welding Unit
8 Components of the Stud Welding Unit Components of the Stud Welding Unit The Visar 650 is ideal for use on construction sites: Protection from damage: – Recessed operation panel – Recessed and slanted connection sockets Sturdy configuration: – Circumferential side frame (bumper)
Page 19: Main Assemblies
The welding time and welding current are fully adjustable. The type plate is located on the backside of the stud welding unit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 20 – Order No./Serial No. – Primary voltage – Fuse – Power consumption – Cooling class – IP code – Date ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 21: Operation Panel And Display
– the stud welding machine being thermally over- loaded. Work can be continued after a short cool- down phase. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 22: Mains Switch
The switch for mains mode is located on the rear of the stud welding unit. 1 - Mains switch ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 23: Welding Process
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. The standards assign this method of joining pin-shaped elements with plane workpieces to the so called ‘Arc Pressure Welding’.
Page 24 : width of about 5 : 1. All technical information and adjustment values are based on the use of welding elements which correspond with current standards. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 25 Protrusion, immersion speed Protrusion, immersion speed (plunge damper from 14 mm (plunge damper from 14 mm diameter) diameter) ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 26 Studs with cone-shaped front area and aluminium ball are preferably used with ceramic ferrule. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 27: Preparing Workplace And Welding Process
‹ Ensure that there is no equipment or apparatus in the working area that could be damaged by weld spatter. ‹ Remove if necessary. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 28: Preparing Surfaces
This ensures a high strength of the welded joints. ‹ Weld the welding element only to a flat surface. ‹ Ask your application consultant at HBS about welded joints on tubes and riffle plates (see page 2). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG...
Page 29: Checking The Stud Welding Gun
‹ Always check the operating manual of your stud welding gun to see whether it may be used with this stud welding unit. This stud welding unit can only be used with the HBS stud welding guns A 12 and A 12-FL.
Page 30: Connection
This can cause the cables to come out of the plug sockets. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 31: Connecting The Welding Gun To The Stud Welding Unit
‹ Plug the ground cable into the corresponding socket of the stud welding unit. ‹ Press in the plug and turn it firmly clockwise (to the right). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 32 ‹ Pay attention to a good contact and symmetrical connec- tion. The welding point should be in the middle between the two ground clamps. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 33: Connecting The Stud Welding Unit To The Mains Supply
‹ Check that the stud welding unit is switched off. ‹ Only now insert the plug into the plug socket. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 34: Welding
These fields can adversely affect the function of medical devices as well as the course of a pregnancy. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 36 Information and recommendations on this can be found in DIN EN ISO 14555. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 37 Information and recommendations on this can be found in DVS 0902. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 38: Setting The Welding Parameters
‹ Read and observe here Point 12.2 „Determining the Welding Time and Welding Current“. ‹ Only now set the welding current ( ) with the knob. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 39: Performing The Welding Process
– Where there is limited mobility on electrically conductive parts – In damp, wet or hot rooms. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 40 ‹ Observe furthermore your working instructions and the accident preventi- on regulations. Glowing hot weld and liquid spatter occur during welding. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 41 The gun head becomes very hot during the welding process. The same applies to the welded element and the workpiece. ‹ Wear your proper protective clothing. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 42: Sleep Mode
– actuating the welding gun start button or – placing the stud welding gun on the workpiece. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 43: 13 Checking The Quality Of The Weld
Decrease current and/or time many spatters Plunging speed too high Adjust plunging depth and/or Welding element too short damping factor ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 44: Carrying Out Bending Test
13 Checking the Quality of the Weld 13.2 Carrying out 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 45 ‹ Grind off hardened workpiece surfaces (e.g. roll hardening). ‹ Check the piston of the welding gun for ease of movement. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 46: Optimisation Of Welding Parameters
‹ If necessary re-adjust the lift and spring pressure. ‹ Refer here to the operating manual of your welding gun. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 47: Blowing Effect And Remedies
(on welding guns with external welding cable) by turning the welding gun about its vertical axis. Blowing effect Cause Remedy ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 48: Troubleshooting
(18 Ω control cable*) specialists to 22 Ω) between Pin 1 and Pin 2*) ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 49 ‹ Please use the form „Service & Support“ in the annex to send in the stud welding unit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 50: Shutting Down
‹ Protect the stud welding unit and its components against the ingress of liquids and foreign matter. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 51: Maintenance And Care
‹ Do not use solvents for cleaning. These can damage the surface of your stud welding unit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 52: Inspection And Tests
‹ Replace any removed or damaged signs: Before opening machine disconnect mains Observe the operating manual Warning of electric shock hazard ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 53: Storage
‹ Dispose of the stud welding unit only via the manufacturer or a specia- list disposal company. ‹ Never dispose of the stud welding unit in the domestic refuse. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 54: Ec Declaration Of Conformity
EC Declaration of Conformity EC Declaration of Conformity in Accordance with Directive 2006/42/EC, Annex II 1 A (Original EC Declaration of Conformity) Herewith the manufacturer HBS Bolzenschweiss-Systeme GmbH & Co. KG Felix-Wankel-Strasse 18 P.O. Box 13 46 85221 Dachau GERMANY...
Page 55: Service & Support
Service & Support Service & Support With the return please attach a copy of the filled out form together with the repair number given by HBS! Repairs without repair number will not be processed. Repair number (given by HBS) Company:...
Page 60 HBS Bolzenschweiss-Systeme GmbH & Co. KG Felix-Wankel-Strasse 18 • 85221 DACHAU • GERMANY Phone +49 8131 511-0 • Fax +49 8131 511-100 • E-mail international@hbs-info.com www.hbs-info.com...

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HBS Visar 650 Operating Manual

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