HBS ONURFIX ARC 800 Operating Manual
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HBS ONURFIX ARC 800 Operating Manual

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ARC 800
Power Unit
93-10-0702A
Operating Manual

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Summary of Contents for HBS ONURFIX ARC 800

  • Page 1 ARC 800 Power Unit 93-10-0702A Operating Manual...
  • Page 2 Customer Service in Germany: 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 www.hbs-info.com ARC 800 Operating Manual, Issue 03/2008 Order No. BA 93-10-0702A 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 stud welding units can be dangerous to life. 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.

  • Page 5: Table Of Contents

    Table of Contents General ..................... 9 Guide to this Operating Manual ..............10 Safety Symbols ..................11 General Safety Instructions ................ 12 Intended Use ....................12 Transportation, Packaging, Storage ............13 Accompanying Documents ................ 13 Markings ..................... 14 Delivery ................... 15 Starting-up ..................
  • Page 6 Switching on the Power Unit ..............32 5.6.1 Adjusting the Welding Time ................... 33 5.6.2 Adjusting the Gas Pre-Flow Time ................33 Welding Procedure ..................33 Checking the Quality of the Weld ............... 34 5.8.1 Visual Inspection ....................35 5.8.2 Bending Test ......................
  • Page 7 Glossary ..................64 Regulations and Standards ............65 Further Instructions ............... 67 Guarantee Clauses ................ 68 EU-Statement of Conformity ............69 Confirmation .................. 70 Feedback ..................71 Service & Support ................. 72 Index ....................73 ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...
  • Page 8 viii ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...

  • Page 9: General

    General Persons addressed by this operating manual This operating manual is written for operators, personnel of the end user, and authorized service technicians. It provides you with all necessary information to operate the power unit. Required user qualification The power unit must only be operated by quali ed personnel Let the power unit only be operated by persons who –...

  • Page 10: Guide To This Operating Manual

    Guide to this Operating Manual This operating manual provides you with the following information "Delivery" in Chapter 2 "Starting-up" in Chapter 3 "Functional Principle" in Chapter 4 "Stud Welding Process" in Chapter 5 "Switching o the Power Unit" in Chapter 6 "Care and Maintenance"...

  • Page 11: Safety Symbols

    Safety Symbols Symbols and markings used in this operating manual mean: Threat to life or risk of personal injury Risk of material damage 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...

  • Page 12: General Safety Instructions

    (place of operation see section 8.1). The welding guns A 12, A 16, AI 06 and CA 08 can be connected to the HBS power unit ARC 800. For details please contact the HBS customer service (address see page ii).

  • Page 13: Transportation, Packaging, Storage

    Transportation, Packaging, Storage HBS delivers products in a speci c transport package. Save the undamaged packing. Ship and transport the device only in its original packing. Right before delivery, the power unit is once again checked for proper functioning and a control mark is attached.

  • Page 14: Markings

    Markings There are various markings and safety symbols attached to your power unit (see section 8.1). Make sure that all markings remain clearly visible. Type plate The type plate contains the following data: Manufacturer Type Order No./Serial No. Primary voltage Fuse Power consumption Cooling class...

  • Page 15: Delivery

    Delivery The basic equipment of your power unit contains the following components: No. of pieces Part Type Order No. Power unit ARC 800 93-10-0702A Operating manual ARC 800 BA 93-10-0702A ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...

  • Page 16: Starting-Up

    Starting-up In this chapter you learn what to observe during setting-up and starting-up of the power unit. Requirements of Workplace Vapors and airborne particles may occur during stud welding operations. Especially with surface treated materials, toxic vapors may be produced. Ensure that a fume extraction is available and that the room is adequately ventilated according to accident prevention regulations.

  • Page 17: Connecting The Power Unit To The Primary Power Supply

    Secure the following safety symbols in the area of welding place: THREAT TO LIFE to persons fitted with a pace maker Strong electro-magnetic fields occur in the vicinity of the stud welding unit during welding. Such fields may affect the proper function of a pace maker.

  • Page 18: Connecting The Welding Gun To The Power Unit

    Connecting the Welding Gun to the Power Unit Switch off the power unit. In this way, you avoid any risk of electrical shock. Plug the welding cable of the welding gun into the socket of the power unit. Press-in the plug and twist rmly clockwise. The connection is not secured against...

  • Page 19: Ground Connection

    Ground Connection Plug the ground cable in the connector of the power unit. Press in the plug and twist rmly clockwise. The connection is not secured against working itself loose! Check the plug connections regularly to ensure that they are properly locked.

  • Page 20: Shielding Gas Connection

    Shielding Gas Connection Observe the standards (see appendix) when handling the shielding gas bottles. Connect the shielding gas bottle as follows: Connect the gas hose of the shielding gas bottle to the gas inlet of the power unit. Connect the gas hose of the welding gun to the gas outlet. Set the ow meter of the shielding gas bottle to 8 - 16 liters/min.

  • Page 21: Function

    Function In this chapter you learn more about the design of the power unit and how to use the various setting options. Components of the Power Unit 4.1.1 Power Unit The power unit consists of the main assemblies Solid-State-Relais Transformer Recti er Control unit Mains alternating current is transformed in the transformer (2) and converted in the...

  • Page 22: Keyboard And Display

    Keyboard and Display Stand-by display green Ready for welding Stand-by display red Locked How to use displays and keys is described in section 5.6. ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...

  • Page 23: Stud Welding Procedure

    Stud Welding Procedure This chapter contains the basics of stud welding, how you must actually proceed, and what must be observed. You learn to select correct welding parameters and which welding elements can be used. Safety Instructions Improper operation of the power unit is LIFE-THREATENING! Threat to life –...
  • Page 24 THREAT TO LIFE by toxic vapors and airborne particles Toxic vapors and airborne particles may occur during stud welding operations, especially with surface treated materials. Ensure that a fume extraction is available that the room is adequately ventilated according to accident prevention regulations. If possible, do not weld in rooms which are lower than 3 meters.
  • Page 25 stud welding unit are prohibited and result in complete cancellation of any guarantee and liability claims against HBS. In case of any accidents whatsoever, advise a physician, your supervisor, and the o cial bodies immediately.

  • Page 26: Functional Principle Of Stud Welding

    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 (see appendix). The standards assign this method of joining pin-shaped elements with plane workpieces to the so called ‘Arc Pressure Welding’...
  • Page 27 – At the beginning of the welding process, the welding element (stud) in the welding gun is lifted clear o the workpiece by a lifting device (solenoid). An initial switched current triggers a pilot arc of a low current power (see position 2). Then the main arc ignites between the face area of the welding element and the workpiece.

  • Page 28: Drawn-Arc Stud Welding With Ceramic Ferrule

    5.2.1 Drawn-Arc stud Welding with Ceramic Ferrule Drawn-arc stud welding with ceramic ferrule is used with welding elements of 3 to 25 mm diameter (preferably above 12 mm diameter) and with welding times of 50 to 2000 ms. It is generally suitable for all welding positions. When stud welding with ceramic ferrule, the welding position is PA (vertical).

  • Page 29: Short-Cycle Drawn-Arc Stud Welding With Shielding Gas

    The shielding gas in uences – the arc and the melting behavior of welding element and workpiece, – the development of the weld collar and the penetration shape via the surface tension. With stud welding with shielding gas, the shape of the weld collar is not reproducible, as the shielding gas has no forming e ects on the melt –...

  • Page 30: Drawn-Arc Capacitor-Discharge Stud Welding

    5.2.4 Drawn-Arc Capacitor-Discharge Stud Welding With drawn-arc capacitor-discharge stud welding, the welding energy is taken from a capacitor. As a result, welding currents are very high and welding times (< 10 ms) very short. 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.
  • Page 31 Determination of welding time 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). Before you use another lot of welding elements, carry out some trial welds to verify the parameter setting.

  • Page 32: Switching On The Power Unit

    Switching on the Power Unit Improper operation of the stud welding unit is LIFE-THREATENING! First read the safety instructions in chapters 1, 3 and 5. Insert the primary plug of the power unit into an appropriate socket. Switch on the power unit with the mains switch. The digital display shows the adjusted charging voltage.

  • Page 33: Adjusting The Welding Time

    5.6.1 Adjusting the Welding Time Refer to the table in section 5.5 for the required welding time matching your welding job. Set the welding time (digital display) with the arrow keys ( higher – lower) on the display. 5.6.2 Adjusting the Gas Pre-Flow Time If working with shielding gas, you have to set the gas pre- ow time.

  • Page 34: Checking The Quality Of The Weld

    During the actual welding process, you must expect red-hot welding spatters, possibly liquid spatters, a flash, and a loud bang may occur > 90dB (A). Inform any collegues who are occupied in the vicinity of the welder about the bang. Wear always your personal protective equipment according to actual standards (see appendix).

  • Page 35: Visual Inspection

    - Plunging speed too high - Adjust plunging depth and/or damping factor 5.8.2 Bending Test You can purchase from HBS a bending device with inserts for various diameters of the welding elements. ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...
  • Page 36 The bending test serves as an easy work sample and as a check for the selected welding parameters. Bend the welding element with the bending device once by 60°. Carry out the test in di erent directions. The bending test is passed if a crack or a fracture of the welded zone does not occur. Please note the instructions on fault recognition and corrective actions in chapter 5.

  • Page 37: Arc Blow Effect

    5.8.3 Arc Blow Effect A so called arc blow e ect can occur with unproportionally distributed ground connec- tions in relation to the base material mass, varying material distribution, or welding at the edge of a workpiece. This is an undesired de ection of the arc. It causes a single- sided melting of the stud material, increased pore formation, and undercuts in the welding area.

  • Page 38: Malfunctions And Corrective Actions

    Malfunctions and Corrective Actions Malfunction Possible cause Fault finding Corrective action Carried out by Primary sw itch does Primary sw itch Check primary sw itch *) Replace primary sw itch *) Qualified personnel not rest in position 1 defective Fuse F4 1 AF for Check voltage supply of primary Replace fuse F4 1 AF *) Qualified personnel...

  • Page 39: Welding Elements

    5.10 Welding Elements The stud welding unit must be suitable for welding the welding elements to be used. Observe the instructions in the operating manuals. Welding elements are mainly manufactured with the cold formed process. We recommend the following standard welding elements (see appendix). Use only welding elements of the same lot.
  • Page 40 Pin UD (S) Diameter Length Chuck Ceramic Shielding gas *) 20-50 mm 83-50-006 83-51-006 20-50 mm 83-50-008 83-51-008 20-80 mm 83-50-010 83-51-010 20-80 mm 83-50-012 83-51-012 25-80 mm 83-50-016 Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303 Pin with internal thread MI (ID) Diameter Length Chuck Ceramic...
  • Page 41 82-50-006 Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303 We look forward to consult you with view to special welding elements and other special materials. HBS Bolzenschweiss-Systeme GmbH & Co. KG Felix-Wankel-Strasse 18 85221 Dachau / Germany Phone +49 (0) 8131 511-0...

  • Page 42: Switching Off The Power Unit

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

  • Page 43: Care And Maintenance

    Care and Maintenance Safety Instructions Let maintenance and repair operations be carried out only by qualified personnel or by your competent service technician. Before starting any repair or maintenance operation, always switch the power unit off and disconnect the primary plug. Do not wear a wrist...

  • Page 44: Open The Power Unit

    Open the Power Unit Open the power unit only if you are sufficiently qualified in repairing electrical equipment. Remove the 10 screws of the casing (5 at each side). Carefully remove the cover and disconnect the ground cable on the inside of the cover.

  • Page 45: Appendix

    Appendix In the appendix, there is information of interest regarding technical data, spare part lists, accessories, standards, etc. Technical Data Power Unit ARC 800 for ARC stud welding according to current standards MR12, dia. 2 to 10 mm (#4 to 1/2", dia. 14 ga to 3/8") Welding material Mild steel, stainless steel Welding rate...

  • Page 46: Spare Parts

    Spare Parts Spare part list power unit type ARC 800 (93-10-0702A) When ordering spare parts, please indicate order number and type of power unit. Pos. Quantity Order No. Description 80-90-184 Tooth lock washer A4 88-11-386 Bottom unit complete 88-10-546 Cover plate 80-90-158 Screw M4 x 6 black 88-11-259A...
  • Page 47 Power unit ARC 800 (93-10-0702A) ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...
  • Page 48 Distance stud 88-10-930A Front lm 80-10-576 Flat connection 80-56-215 Capacitor 80-70-278 Connection cable 80-70-279 Connection cable 80-11-111 Cage nut M4 80-11-754 HBS-Logo small 80-11-359 Conductor mark ground cable * see sticker “Controller” ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...
  • Page 49 Front plate complete ARC 800 (88-11-268A) ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...
  • Page 50 Spare part list support unit complete ARC 800 (88-11-387) Pos. Quantity Order No. Description 80-90-320 Screw M6 x 20 80-90-197 Tooth lock washer A6 80-90-146 Nut M6 88-11-262 Angled support plate 80-90-198 Washer 6 mm 80-90-147 Spring washer 6 mm 80-11-670 Cable mounting 80-11-669...
  • Page 51 80-57-332 Resistor L 80-90-202 Washer 5 mm 80-90-127 Screw M5 x 8 88-11-252 Transformer 400 V 80-80-491 P.C. board ARC transformer 80-55-021 Solid State Relay 80-70-346 Varistor 80-70-345 Varistor 80-11-359 Conductor mark ground cable ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...
  • Page 52 Spare part list rear wall complete ARC 800 (88-11-259A) Pos. Quantity Order No. Description 88-16-456 Rear wall 80-10-0960 ZEVB-Screwing 80-11-567 Lock nut 80-50-049 80-90-108 Screw M4 x 12 80-90-121 Spring washer 4 mm 80-90-184 Tooth lock washer A4 80-11-359 Conductor mark ground cable ARC 800 Order No.
  • Page 53 Rear wall complete ARC 800 (88-11-259A) ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...
  • Page 54 Spare part list bottom unit complete ARC 800 (88-11-386) Pos. Quantity Order No. Description 80-11-437 Cage nut M4 88-11-256 Bottom plate 80-10-203 Casing feet 80-90-173 Screw M4 x 10 80-90-164 Washer 4 mm 88-11-258 Resis tor support 80-90-152 Screw M5 x 10 80-90-128 Spring washer 5 mm 80-90-202...
  • Page 55 Bottom unit complete ARC 800 (88-11-386) ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...
  • Page 56 Spare part list shielding gas module ARC 800 (93-50-020) Pos. Quantity Order No. Description 80-10-145 Connector female 80-10-024 Nipple 80-10-139 Connector male 80-10-146A Solenoid valve 88-11-839 Connection cable 80-10-143 Connector female 0.26 m 80-10-182 Plastic hose ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...
  • Page 57 Shielding gas module ARC 800 (93-50-020) ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...
  • Page 58 Changing the electronic board Changing the electronic board may only be carried out by sufficiently qualified personnel or by your service technician. Before starting any repair or maintenance operation, always switch the power unit off and disconnect the primary plug. Do not wear a wrist...
  • Page 59 Remove the two spacers. Replace the electronic board. For re-assembly, proceed in reversed sequence. Replacement of the electronic board 80-80-497 See changing the electronic board 80-80-490. In addition, you must remove the two spacers. Replace the electronic board 80-80-497. Please observe the program version! ARC 800 Order No.
  • Page 60 Main board (80-80-497) Please observe the program version! ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...
  • Page 61 Transformer board (80-80-491) ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...

  • Page 62: Electrical Circuit Diagram

    Electrical Circuit Diagram ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...

  • Page 63: Environmentally Admissible Disposal

    Environmentally Admissible Disposal After repair of the power unit, dispose replaced parts in an environmentally admissible way. Used materials: Steel Nonferrous metals (brass, copper) Plastics Aluminum ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...

  • Page 64: Glossary

    Glossary Arc: Electrical discharge at its own between two electrodes under su ciently high current. Whitish light is emitted. The arc generates very high temperatures. Automatic welding head: Device to weld welding elements Capacitor: A component which serves as storage of electrical charge Power unit: Device to provide electrical energy for stud welding...

  • Page 65: Regulations And Standards

    Regulations and Standards The regulations and standards are recommendations and don`t purport to be completely. Standards, regulations Description Stud welding (fundamentals) DIN EN ISO 13918 Welding - Studs and ceramic ferrules for arc stud welding DIN EN ISO 14555 Welding - Arc stud welding of metallic materials DIN EN 1418 Welding personnel - Approval testing of welding operators for fusion welding and resistance weld...
  • Page 66 Machine safety 73/23/EWG Electrical equipment designed for use within certain voltage limits 2004/108/EG EMC-Guidelines 98/37/EG Machine guidelines DIN EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General requirements DIN EN 60529 Degrees of protection provided by enclosures (IP code) DIN EN 60974-1 Arc welding equipment - Part 1: Welding power...

  • Page 67: Further Instructions

    Further Instructions Welding elements, abbreviations, materials, standards, mechanical properties to actual standards Abbreviations for Mechanical Stud types studs (ceramic Material Norm characteristics ferrules) Threaded stud PD (PF) Mild steel (4.8 ISO 898-1 see ISO 898-1 Threaded stud w ith reduced RD (RF) shaft Draw n arc...

  • Page 68: Guarantee Clauses

    Warning: Unauthorized interference with the stud welding unit as well as unauthorized alteration of the stud welding unit are prohibited and result in complete cancellation of any guarantee and liability claims against HBS. Please fill in the serial number: Serial number automatic welding head: ..........

  • Page 69: Eu-Statement Of Conformity

    This is to certify, that equipment listed below is designed and manufactured in conformance to the safety and health regulations. This statement is invalid if any modifications are done on the equipment without prior written approval by HBS. Description of equipment: Power Unit Order No:...

  • Page 70: Confirmation

    Confirmation Herewith I con rm that I have read and understand the present operating manual completely. Date Name ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________...

  • Page 71: Feedback

    Feedback HBS Bolzenschweiss-Systeme Sender: GmbH & Co. KG __________________________ 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 ___________________________________________...

  • Page 72: Service & Support

    Service & Support ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...

  • Page 73: Index

    Index accident prevention ......12, 24 ear protection ......... 9, 24 accident prevention regulations .... 16 electrical circuit diagram ...... 62 accidents ..........25 electrical shock, risk of ....... 18 accompanying documents ....13 electrical voltage ......11, 14 airborne particles .........
  • Page 74 production ..........9 program version ...... 48, 59, 60 liability, any ......12, 25, 68 protective apron ........24 liquid spatters ........34 protective equipment ...... 17, 25 liquids, combustible ......16 protective equipment, personal ....9 locked ..........22 protective gloves ........
  • Page 75 technical data ........ 10, 45 test welding ......... 30 threat to life ......... 10 thyristor ..........64 torque ..........31, 67 training according to current standards ..9 transformer .......... 21 transformer board ........ 61 transportation ........9 transportation, packaging, storage ..
  • Page 76 ARC 800 Order No. BA 93-10-0702A Issue 01.03.08...
  • Page 78 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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