HBS ONURFIX IT 1002 Operating Manual
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HBS ONURFIX IT 1002 Operating Manual

Power unit ceramic/gas version
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IT 1002
Power Unit
Ceramic/Gas Version
93-66-1202
Operating Manual

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  • Page 1 IT 1002 Power Unit Ceramic/Gas Version 93-66-1202 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 IT 1002 Operating Manual, Issue 06/2008 Order No. BA 93-66-1202 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 Determination of Welding Parameters ............31 Switching on the Power Unit ..............33 5.6.1 Adjusting the Welding Time ................... 35 5.6.2 Adjusting the Welding Current ................35 5.6.3 Adjusting the Gas Pre-Flow Time ................35 5.6.4 Library Mode ......................36 5.6.5 Electrode Mode ......................
  • Page 7 Glossary ..................64 Regulations and Standards ............65 Further Instructions ............... 67 Guarantee Clauses ................ 68 Confirmation .................. 69 Feedback ..................70 Service & Support ................. 71 Index ....................72 IT 1002 Order-No. BA 93-66-1202 Issue 01.06.08...
  • Page 8 viii IT 1002 Order-No. BA 93-66-1202 Issue 01.06.08...

  • 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 IT 1002. 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 IT 1002 93-66-1202 Operating Manual IT 1002 BA 93-66-1202 IT 1002 Order No. BA 93-66-1202 Issue 01.06.08...

  • 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 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 Mains switch Control unit EMC- lter IGBT switch...

  • Page 22: Control Unit

    4.1.2 Control Unit The control unit synchronizes the mechanical sequence (lifting the welding element) with the electronic control (ignition of pilot arc, ignition of main arc, sequence of welding time). The welding time is stepless adjustable. Keyboard and Display How to use displays and keys is described in section 5.6. IT 1002 Order No.

  • 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

    (see appendix). 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: Drawn-Arc Stud Welding With Shielding Gas

    5.2.2 Drawn-Arc Stud Welding with Shielding Gas Drawn-arc stud welding with shielding gas is used with welding elements for a diameter range of 3 to 12 (16) mm and with welding times from 50 to 2000 ms. Principally, it is suitable for all welding positions, however, it is preferably used in vertical position PA.

  • Page 30: Short-Cycle Drawn-Arc Stud Welding With Shielding Gas

    5.2.3 Short-Cycle Drawn-Arc Stud Welding with Shielding Gas Short-cycle drawn-arc welding with shielding gas is used for welding elements within a diameter range of 3 to 12 mm (nominal diameter without ange) and welding times between 5 and 100 ms. Due to the short welding times, the energy input and the weld pool are so small that also welding elements up to 12 mm diameter can be welded on thin workpieces.

  • Page 31: Welding Preparation

    Welding Preparation Read the safety instructions in chapters 1, 3, and 5. Observe the workplace requirements (chapter 3, ”Starting-up"). Check all cables and connections for proper condition. Replace immediately defective cables and cable connections to avoid electrical shocks. Check the chuck for proper seat (see operating manual of according welding gun).
  • Page 32 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 33: Switching On The Power Unit

    Further notes on – welding elements – prestress at installation (tie load) and torque – material combinations see appendix and operating manual of the according welding gun. Switching on the Power Unit Improper operation of the stud welding unit is LIFE-THREATENING! First...
  • Page 34 The digital display shows the adjusted welding time and welding current. There is a luminous indication (LED) to the right of the display: Yellow – lights if the welding gun button is triggered Yellow – lights if there is electrical contact between welding element and workpiece –...

  • Page 35: Adjusting The Welding Time

    5.6.1 Adjusting the Welding Time Set the welding time (digital display ) with the arrow keys ( longer – shorter) on the display. 5.6.2 Adjusting the Welding Current Set the welding current (digital display ) with the arrow keys ( higher – lower) on the display.

  • Page 36: Library Mode

    5.6.4 Library Mode In the library mode, you can call up and modify charging voltages, depending on stud diameter (UD/Pins). Simultaneously press both arrow keys of welding time ( shorter , longer), for about one second. The display welding time shows 0-06 (06 means the set welding current and welding time for stud diameter of 6 mm).

  • Page 37: Welding Procedure

    Welding Procedure Improper operation of the stud welding unit is LIFE-THREATENING! The stud welding unit must only be operated by qualified personnel (see chapter 1). Observe the safety instructions in chapters 1, 3 and 5. Prepare the stud welding unit, the ground connection, and the workpiece according to the instructions given in the operating manual.

  • Page 38: Checking The Quality Of The Weld

    Checking the Quality of the Weld You can check the quality of the weld by means of a visual inspection and a bending test. See also actual standards in the appendix “Arc stud welding of metallic materials“, in section irregularities and corrective actions.

  • Page 39: Bending Test

    5.8.2 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. Bend the welding element with the bending device once by 60°.
  • Page 40 Bending Test Type of fracture Possible cause Corrective actions Base material buckling - Correct parameters - none Fracture in welding element - Correct parameters - none above weld collar Fracture in the weld metal - Welding energy too low - Increase welding energy Many pores - Plunging speed too low - Increase plunging speed...

  • Page 41: 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 42: 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 43: 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 44 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 45 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 46: 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 47: 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 48: Open The Power Unit

    Open the Power Unit Open the power unit only if you are sufficiently qualified in repairing electrical equipment. Remove the 14 screws of the casing (5 at each side and 4 on top of casing cover). Carefully remove the cover and disconnect the ground cable on the inside of the cover.

  • Page 49: Appendix

    Appendix In the appendix, there is information of interest regarding technical data, spare part lists, accessories, standards, etc. Technical Data Power Unit IT 1002 for ARC stud welding according to current standards 5/8", dia. 14 ga to 9/16") M3 to MR16, dia. 2 to 14 mm Welding material Mild steel, stainless steel, aluminum Welding rate...

  • Page 50: Spare Parts

    Label mat black 88-10-546 Cover plate 80-10-857 Handle A=300 80-10-159 80-10-115 80-11-359 Conductor mark 80-11-754 HBS Logo small 37 x 28 80-90-199 Screw M5 x 12 80-90-128 Spring washer 5 mm 80-90-188 Nut M5 80-90-197 Tooth lock washer A6 80-90-198...
  • Page 51 Power unit IT 1002 (93-66-1202) IT 1002 Order No. BA 93-66-1202 Issue 01.06.08...
  • Page 52 Spare part list front plate complete IT 1001/IT 1002 (88-13-163) Pos. Quantity Order-No. Designation 88-13-160 Ope ration plate 88-13-164 Front lm operation plate 80-80-558 Electronic board 80-11-987 Distance sleeve 80-11-415 Distance stud 80-11-111 Cage nut M4 80-11-121 Flat connection 80-90-386 Screw M6 x 14 80-90-197 Tooth lock washer A6...
  • Page 53 Front plate complete IT 1001/IT 1002 (88-13-163) IT 1002 Order No. BA 93-66-1202 Issue 01.06.08...
  • Page 54 Spare part list supply module complete IT 1002 (88-17-997) Pos. Quantity Order-No. Designation 88-14-166 Support angular plate 88-13-178 Clamp angle 88-14-167 Cable channel 88-14-168 Angle 88-16-406 Transformer 480 V 80-80-597 P.C. board 80-50-927 Mains interference lter 80-80-557 P.C. board 80-56-041 Capacitor 80-57-332 Resistor L...
  • Page 55 Supply module complete IT 1002 (88-17-997) IT 1002 Order No. BA 93-66-1202 Issue 01.06.08...
  • Page 56 Spare part list shielding gas module IT1001/IT 1002 (88-13-167) Pos. Quantity Order-No. Designation 80-10-145 Connector female 80-10-0916 Swivel connection 80-10-167 Screwing 80-10-240 Connector male 80-10-146 Solenoid valve 80-10-1073 Lock nut G1/4” 80-10-143 Connector female 0.26 m 80-10-182 Plastic hose IT 1002 Order No. BA 93-66-1202 Issue 01.06.08...
  • Page 57 Shielding gas module IT 1001/IT 1002 (88-13-167) IT 1002 Order No. BA 93-66-1202 Issue 01.06.08...
  • Page 58 Spare part list terminal plate complete IT 1002 (88-18-013) Pos. Quantity Order-No. Designation 88-18-014 Terminal plate 80-50-035 Mounting sleeve 80-10-0960 Screwed cable connection 80-11-567 Lock nut M25 x 1,5 80-50-480 Primary switch 80-50-041 Control cable sleeve 80-10-0173 Clip-on ferrite 80-11-111 Cage nut M4 80-10-576 Flat connection...
  • Page 59 Terminal plate complete IT 1002 (88-18-013) IT 1002 Order No. BA 93-66-1202 Issue 01.06.08...
  • Page 60 Spare part list power unit complete IT 1002 (88-17-929) Pos. Quantity Order-No. Designation 88-14-158 Bottom plate 88-13-170 Rear wall 88-14-159 Screen angle plate 88-14-160 Intake channel 80-70-429 Power unit 80-10-203 Casing feet 80-11-111 Cage nut M4 80-11-121 Flat connection 80-11-358 Conductor mark 80-11-359 Conductor mark...
  • Page 61 Power unit complete IT 1002 (88-17-929) IT 1002 Order No. BA 93-66-1202 Issue 01.06.08...

  • Page 62: Electrical Circuit Diagram

    Electrical Circuit Diagram IT 1002 Order No. BA 93-66-1202 Issue 01.06.08...

  • 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 IT 1002 Order No. BA 93-66-1202 Issue 01.06.08...

  • 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: Confirmation

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

  • Page 70: 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 71: Service & Support

    Service & Support IT 1002 Order No. BA 93-66-1202 Issue 01.06.08...

  • Page 72: 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 73 production ..........9 protective apron ........24 liability, any ......12, 25, 68 protective equipment ...... 17, 25 library mode ........36 protective equipment, personal ....9 liquid spatters ........37 protective gloves ........24 liquids, combustible ......16 protective goggles ........
  • Page 74 technical data ........10, 49 threat to life ......... 10 thyristor ..........64 torque ..........33, 67 training according to current standards .. 9 transportation ........9 transportation, packaging, storage ..13 type plate ........14, 17 unauthorized use ........9 user quali cation, required .....
  • Page 76 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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