Related Manuals for HBS ARC 800
Summary of Contents for HBS ARC 800
- Page 1 ARC 800 Stud Welding Unit 93-10-0702A 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 ARC 800 Operating Manual Issue 2021-01 Order No. E-BA 93-10-0702A 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.
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Page 4: Table Of Contents
Connecting the Ground Cable ................36 11.4 Connecting the Stud Welding Unit to the Mains Supply ........37 ©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 ....................57 EC Declaration of Conformity ................58 Service & Support ....................59 Index ........................60 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
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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.
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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...
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Page 13: Scope Of Supply
‹ Report any transport damage or missing components immediately to the delive- ring shipping agent or the dealer (address, see page 2). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 14: Accessories
*) recommended welding range ARC 800 / 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 *) recommended welding range ARC 800 / 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 16 (Shielding gas shroud PSS-1) not included in delivery *) recommended welding range ARC 800 / 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...
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Page 17: Technical Data
5 Technical Data Technical Data Stud welding unit ARC 800 for ARC stud welding according to current standards Welding range Dia. 2 to 10 mm, M3 to M12 (Type RD) Welding material Mild steel, stainless steel Welding rate 7 to 17 studs/min (depending on application and stud dia.) -
Page 18: 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, A 12-FL, A 16 and CA 08. -
Page 19: 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 20: Components Of The Stud Welding Unit
The welding time is stepless 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 21 – 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...
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Page 22: Control Panel And Display
The welding time is shown at the display (1). longer (2) - shorter (4)). The welding time is set with the arrow keys ( ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 23: Led Display
Yellow lights if there is electrical contact between welding element and workpiece ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 24: 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 25 : 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 26 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 27 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 28 EN ISO 13918. Welding elements with cone-shaped front area and without an aluminum ball are preferably used. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 29 To minimize pore formation, the use of shielding gas for stud diameters upwards of 8 mm is recommended. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
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Page 30: 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 31: 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 32: 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, A 12-FL, A 16 and CA 08. -
Page 33: 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 34: Connecting The Stud Welding Gun To The Stud Welding Unit
‹ Therefore always check that the plug connector is firmly inserted. This prevents a poor contact and hence overheating of the plug connectors. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 35: Shielding Gas Connection
The valve would be destroyed. If the conduits are wrongly connected, feeding and welding malfunc- tions will occur. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 36: Connecting The Ground Cable
‹ 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 37: 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 38: Welding
1 - Mains switch ‹ Only now switch on the stud welding unit at the mains switch (1). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 39: Determining The Welding Time
The welding time should be as short as possible in the case of welding wit- hout weld pool protection. Welding energy is only selected by welding time. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 40 When using alloyed steels, the welding energy (welding time) must be reduced by about 10 %. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
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Page 41: Checking Shielding Gas Flow Rate
The flow meter displays the amount of shielding gas flowing in l/min. ‹ Set the flow rate according to your welding task. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 42: Setting The Welding Parameters
Insufficient gas pre-flow times may inhibit the shielding function of the gas. Both lead to poor welding results. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 43: 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 44 ‹ 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 45 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 46 ‹ Now check the quality of the welded joint before inserting a new welding element and repeating the welding process. ‹ Work in accordance with the following point 13. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
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Page 47: 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 48: 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 49 ‹ 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...
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Page 50: 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 51: 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 52: Troubleshooting
Control cable broken Check control cable for Replace control cable*) Qualified specialists electrical flow*) ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 53 ‹ 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...
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Page 54: 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 55: Maintenance And Care
The inside of the stud welding unit must be cleaned at least every three months. ‹ Inform your dealer or your maintenance department. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 56: 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 57: 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 58: 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 59: 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: Index
....13 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 61 ......12 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 62 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 64 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...