Related Manuals for HBS IT 2002
Summary of Contents for HBS IT 2002
- Page 1 IT 2002 Stud Welding Unit Ceramic/Gas Version 93-60-2202 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 IT 2002 Operating Manual Issue 2021-01 Order No. E-BA 93-60-2202 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
Switching on the Stud Welding Unit ..............37 12.2 Determining the Welding Time and the Welding Current ........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 ....................62 EC Declaration of Conformity ................63 Service & Support ....................64 Index ........................65 ©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 delivering 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
A 25 with adaptor 88-16-760 Ground cable 5 m, 120 mm² 93-40-080 with adaptor 88-16-760 for A 25 2 pieces necessary ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – full or partial reproduction subject to prior approval of the manufacturer... -
Page 15: Technical Data
5 Technical Data Technical Data Stud welding unit IT 2002 for ARC stud welding according to current standards Series Welding range Dia. 2 to 22 mm, M3 to M24 Welding material Mild steel, stainless steel, aluminium Welding rate Dia. 22 = 6 studs/min... -
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, A 16, A 22, A 25 and AI 06. -
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
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). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 19 – 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 20: Control Panel And Display
The condition of the welding unit is monitored after switching-on. After self-test, the digital displays show the last set welding time (1) and welding current (2). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 21 – if there is a malfunction of the power element. Lights, automatic mode is switched on (not available) Green Lights, shielding gas is switched on ©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: 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 23 : 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 24 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 25 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 26 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 27 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 28: 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 29: 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 30: 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 AI 06, A 12, A 16, A 22 und A 25. -
Page 31: 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 32: Connecting The 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 33: 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 34: 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 35: 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 36: 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 37: Switching On 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 38 Information and recommendations on this can be found in DVS 0902. We recommend the “drawn arc stud welding with shielding gas” welding procedure. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 39 Information and recommendations on this can be found in DVS 0902. We recommend the “drawn arc stud welding with shielding gas” welding procedure. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 40 Shielding gas according to DIN EN ISO 14175-M21, see chapter 9 “Welding Process” We recommend the “drawn arc stud welding with ceramic ferrule” welding procedure. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 41 Shielding gas according to DIN EN ISO 14175-M21, see chapter 9 “Welding Process” We recommend the “drawn arc stud welding with ceramic ferrule” welding procedure. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 42 Information and recommendations on this can be found in DVS 0902. Shielding gas according to DIN EN ISO 14175-I1/HBS recommendation, see chapter 9 “Welding Process”; for better welding results, we recommend changing the polarity of the welding voltage by reversing the welding current and ground cables.
- Page 43 When welding without weld pool protection, the welding time should be se- lected as short as possible. The welding energy is selected through the welding time alone. ©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 44: Checking Shielding Gas Flow Rate
The flow meter displays the amount of shiel- ding 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 45: Possible Settings
‹ Read and observe here Point 12.2 „Determining the Welding Time and Welding Current“. ‹ Only now set the welding current (digital display ) 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 46: Adjusting The Gas Pre-Flow Time
LED is off. In this way, the gas valve remains closed during the welding procedu- ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 47: Library Mode
The display welding current shows the current scale without dots: 1 9 4 0 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 48: 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 49 ‹ 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 50 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 51 ‹ 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 52: 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 53: 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 54 ‹ 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 55: 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 56: 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 57: 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 58 ‹ 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 59: 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 60: 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 61: 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 62: 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 63: 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 64: 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 65: Index
....45 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 66 ......12 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 68 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...