HBS ARC 1550 Operating Manual

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ARC 1550

Power Unit

93-10-1552A

Operating Manual

©HBS Bolzenschweiss-Systeme GmbH & Co. KG

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Page 2 +49 8131 511-100 E-mail post@hbs-info.com www.hbs-info.com ARC 1550 Operating Manual Issue 2012-07 Order No. E-BA 93-10-1552A Translation of the Original Operating Manual 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 unit from HBS Bolzenschweiss-Systeme. We from HBS wish you every success at all times when working with this stud wel- ding unit. The high level of quality of our products is guaranteed by the ongoing further deve- lopment in the design, equipment and accessories.
Page 4: Table Of Contents
Welding ..................... 35 12.1 Switch on the Power Unit ..................35 12.2 Determining the Welding Time ................36 ©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...
Page 6: Important Safety Precautions
You will otherwise endanger yourself. This can lead to serious injury or extensive 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 ‹ Ensure that an approved fire extinguisher is available at the place of work. ©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 unit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 9: Symbols And Terms Used
This symbol prompts you to wear ear protectors. 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 10 Have a fire extinguisher suitable 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 11 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 12: 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 13: Accessories
No. of Part Type Order No. pieces Ground cable 5 m, 50 mm² 93-40-013 (2 pieces required) ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 14: Technical Data
5 Technical Data Technical Data Stud Welding Unit ARC 1550 for ARC stud welding according to current standards Welding range M3 - M20 RD, Ø 2 - 19 mm Welding material Mild steel, stainless steel Welding rate 3 to 35 studs/min (depending on application...
Page 15: Intended Use
Any other use will result in the desired strength of the welded joint being reduced. The HBS welding guns A 12, A 16, A 22 and AI 06 may only be connected to this power unit. The intended use also implies observance of the operating manual on the welding gun used and compliance with the intervals and conditions for inspection and main- tenance of the power unit and the components employed.
Page 16: Warranty
The same applies analogously 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 17: Components Of The Power Unit
The welding time is stepless adjustable. The type plate is located on the backside of the power unit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 18 – 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 19: Keyboard And Display
The welding time is shown at the display (1). The welding time is set with the arrow keys ( longer (2) - shorter (4)). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 20: 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 21: Welding Process
– The energy source (welding rectifier supplied by mains, inverter, capacitor battery). 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...
Page 22 : 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 23 Spring pressure (arc length) (arc length) (arc length) (plunging speed) Plunging depth Plunging depth Plunging depth Plunging depth ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 24 Studs with cone-shaped front area and aluminum 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 25 Studs with cone-shaped front area preferably used under shielding gas. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 26 Normally, a weld pool protection is not required. The process is mainly used for welding elements in a diameter range of up to 8 mm. ©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 Place Of Work 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 Welding Gun
‹ Always check the operating manual of your welding gun to see whether it may be used with this power unit. The HBS welding guns A 12, A 16, A 22 und AI 06 may only be connected to this power unit.
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 Power 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 32: 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 33: Shielding Gas Connection
The valve would be destroyed. If the conduits are wrongly connected, feeding and welding mal- functions 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 Power Unit To The Mains Supply
‹ Check that the power 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 35: Welding
1 - Multiple-contact switch 2 - Mains switch Only now switch on the power unit at the mains switch (2). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 36: Determining The Welding Time
(I[A] = min. 100 x Ø (mm)). The welding time should be as short as possible in the case of welding without weld pool protection. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 37 UD / Pins 1,000 UD / Pins 1,200 Ø d 1,000 1,200 to be checked by test weldings ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 38 1,200 DD/PD (MD) 18.38 1,550 Ø d Ø d 1,000 1,200 to be checked by test weldings ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 39 UD / Pins 5/8“ 1,200 Ø d 3/8“ 4/8“ 1,000 5/8“ 1,200 to be checked by test weldings ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 40 #10 / 3/16 3/16“ 1/4“ 1/4“ 0.27 5/16“ 0.35“ 1,000 3/8“ 0.43“ 1,200 to be checked by test weldings ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 41: Setting The Welding Time
If you want to quit the enabled energy control without reference wel- ding, trigger a lift process. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 42: Adjusting The Gas Pre-Flow Time
‹ If you are working without shielding gas, set the gas pre-flow time 2 ... 00. The gas valve remains closed 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 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 If you pull the welding gun away at an angle, you will strain the chuck and shorten its service life. ©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...
Page 47: 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...
Page 50: Optimization 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 Qualified specialists electrical flow*) cable*) ©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 pow- er unit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 54: Shutting Down
‹ Disconnect the control cable and welding cables from the power unit. ‹ Protect the power 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
‹ Add a little household detergent to the cleaning water. ‹ Do not use solvents for cleaning. These can damage the surface of your power unit. ©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 power unit only via the manufacturer or a specialist disposal company. ‹ Never dispose of the power 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 sending please attach a copy of the filled out form togehter with the repair number given by HBS! Repairs without repair number will not be handled. Repair number (given by HBS) Company:...
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 post@hbs-info.com www.hbs-info.com...

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93-10-1552a

HBS ARC 1550 Operating Manual

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