HBS ONURFIX C 08 Operating Manual
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HBS ONURFIX C 08 Operating Manual

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C 08
Welding Gun
92-20-256
Operating Manual

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  • Page 1 C 08 Welding Gun 92-20-256 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 C 08 Operating Manual, Issue 03/2008 Order No. BA 92-20-256 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 ..................... 7 Guide to this Operating Manual ..............8 Safety Symbols .................... 9 General Safety Instructions ................ 10 Intended Use ....................10 Transportation, Packaging, Storage ............11 Accompanying Documents ................ 11 Markings ..................... 12 Delivery ................... 13 Starting-up ..................
  • Page 6 Malfunctions and Corrective Actions ............33 Welding Elements ..................34 Switching off the Welding Gun ............. 36 Temporary Switching off ................36 Disposal ..................... 36 Care and Maintenance ..............37 Safety Instructions ..................37 Regular Maintenance Operations ............... 38 Appendix ..................39 Technical Data ....................

  • Page 7: 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 welding gun. Required user qualification The welding gun must only be operated by qualified personnel. Let the welding gun only be operated by persons who –...

  • Page 8: 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 off the Welding Gun“ in Chapter 6 “Care and Maintenance“...

  • Page 9: 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 10: General Safety Instructions

    (place of operation see section 8.1). The welding gun C 08 can be connected to the HBS power units CD 1501, CD 2301, CD 3101, CDM 1601, CDM 2401 and CDM 3201. For details please contact the HBS customer service (address see page ii).

  • Page 11: Transportation, Packaging, Storage

    Transportation, Packaging, Storage HBS delivers products in a specific transport package. Save the undamaged packing. Ship and transport the device only in its original packing. Right before delivery, the welding gun is once again checked for proper functioning and a control mark is attached. When receiving the delivery, check everything for damages and completeness.

  • Page 12: 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 13: Delivery

    Delivery The basic equipment of your welding gun contains the following components: No. of pieces Part Type Order No. Gun cable length 6.5 m C 08 92-20-256 Operating manual C 08 BA 92-20-256 C 08 Order No. BA 92-20-256 Issue 01.03.08...

  • Page 14: Starting-Up

    Starting-up In this chapter you learn what to observe during setting-up and starting-up of the welding gun. Requirements of Workplace The welding gun protection is to class IP 20. Do not use the welding gun in humid environment! Vapors and airborne particles may occur during stud welding operations.

  • Page 15: Connecting The Welding Gun To The Power Unit

    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 16: Ground Connection

    Plug the control cable of the welding gun into the appropriate connection of the power unit. Twist the retaining nut of the control cable connector clockwise to secure the connection. The welding gun cables must not be coiled during welding. Coiled cables work as a coil and may negatively affect the welding result.

  • Page 17: Change Working Place

    Connect the ground clamps to the workpiece as securely as possible. Take care to ensure good contact and symmetrical connec- tion. The welding location must lie directly between the two ground clamps. Change Working Place Switch off the power unit. In this way, you avoid any risk of electrical shock.

  • Page 18: Function

    Function In this chapter you learn more about the design of the welding gun and how to use the various setting options. Components of the Welding Gun The body of the welding gun consists of a sturdy two-part plastic housing (1). The control cable and the welding cable (2) are connected through the welding gun handle to the welding gun.

  • Page 19: Adjustment Of Chuck

    Adjustment of Chuck Various chucks for different stud diameters are available as unit accessories (see appendix). Select the chuck which fits the diameter of your welding element. Put the welding element into the chuck. In the chuck, there is an adjustable stop pin.

  • Page 20: Installation Of Chuck

    Retighten the retaining nut. Retighten regularly and carefully the chuck at the four segments (see figure below, at the visible end of the chuck) using pliers to ensure a proper current transition. This will prevent early wear through spark erosion. Installation of Chuck Put the chuck with loose retaining nut up to the stop into the piston of the welding gun.

  • Page 21: Adjustment Of Spring Force

    Adjustment of Spring Force The adjustment piece spring force can be turned by max. 360°. Forced turning with noticeable resistance of the adjustment piece spring force can result in mechanical damage of components. Twist the adjustment piece spring force clockwise, until the ‘min’ position is reached.

  • Page 22: 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 23 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 24 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 official bodies immediately.

  • Page 25: Functional Principle Of Stud Welding

    Functional Principle of Stud Welding Stud welding with tip ignition is divided into gap stud welding and contact stud welding. 5.2.1 Contact Stud Welding – The welding gun is placed onto the workpiece (figure 5.2.1, position 1). The welding element which projects above the welding gun support legs, is pushed back tensioning a pressure spring.

  • Page 26: 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 power unit). Before welding, make sure that the bellows are checked for damage and proper seat.
  • Page 27 Example: welding parameters for welding gun C 08 in connection with power unit CD 1501 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).

  • Page 28: 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 29: 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 5.7.1 Visual Inspection...

  • Page 30: Bending Test

    5.7.2 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. The welded joint is stressed by bending in a non-defined way.
  • Page 31 Bending Test Type of fracture Possible cause Corrective actions Base material buckling - Correct parameters - none Fracture in the welding element - Correct parameters - none above flange Fracture in the weld metal - Heat input too low - Increase charging voltage - Plunging speed too low - Increase plunging speed - Welding element/base material...

  • Page 32: Arc Blow Effect

    5.7.3 Arc Blow Effect A so called arc blow effect 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 deflection of the arc. It causes a single- sided melting of the stud material, increased pore formation, and undercuts in the welding area.

  • Page 33: Malfunctions And Corrective Actions

    Malfunctions and Corrective Actions Malfunction Possible cause Fault finding Corrective action Carried out by Welding elements Wrong w elding Check charging Change adjusted Instructed personnel not firmly attached parameters selected voltage on pow er unit parameters Check spring force of Change adjusted Instructed personnel w elding gun...

  • Page 34: Welding Elements

    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 manufactured with the cold formed process have a flange and an ignition tip (see actual standards in the appendix). During welding, the flange prevents the arc getting to the cylindric part of the welding element and increases simultaneously the welding area.
  • Page 35 Ø 3 Material: St2k70 galvanized 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 36: Switching Off The Welding Gun

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

  • Page 37: Care And Maintenance

    Care and Maintenance This chapter shows care and maintanance of the welding gun to provide long life expectancy. Safety Instructions Let maintenance and repair operations be carried out only by qualified personnel or by your competent service technician. Before you start any cleaning and maintenance operation with welding gun, switch off...

  • Page 38: Regular Maintenance Operations

    Regular Maintenance Operations Any maintenance and repair operation should only be carried out by qualified personnel or by your competent service technician. You must only carry out the following service operations. Before starting welding, check welding cable and control cable for faults and damage.

  • Page 39: Appendix

    Appendix In the appendix, there is information of interest regarding technical data, spare part lists, accessories, standards, etc. Technical Data Welding Gun Type C 08 for CD stud welding according to current standards M8, dia. 2 to 8 mm (#4 to 5/16'', dia. 14 ga to 5/16") other dimensions on request...

  • Page 40: Spare Parts

    Spare Parts Spare part list welding gun type C 08 (92-20-256) When ordering spare parts, please indicate order number and type of welding gun. Pos. Quantity Order No. Description 88-10-673B Basic shell, complete 80-09-045 Cover shell 80-11-270 Screw EJOT A30x8 80-11-271 Screw EJOT A30x12 80-50-014...
  • Page 41 Welding gun type C 08 (92-20-256) C 08 Order No. BA 92-20-256 Issue 01.03.08...

  • Page 42: Accessories

    Accessories When ordering accessories, please indicate order number and type of welding gun. Description Order No. ------------------------------------------------------------------------------------------------------------------------------------------------------------------ Socket wrench 80-40-085 Chuck Threaded stud PT 82-50-002 M2,5 82-50-025 82-50-003 82-50-004 82-50-005 82-50-006 82-50-008 82-50-009 Pin UT Ø 3 mm 82-50-003 Ø 4 mm 82-50-004 Ø...
  • Page 43 Description Order No. ------------------------------------------------------------------------------------------------------------------------------------------------------------------ Chuck Flat pin + 6.3 mm 82-50-050 Double flat pin Chuck ISO-nail Ø 2 mm 82-50-020 Ø 3 mm 82-50-030 Welding of welding Angle PWA 82-40-011 elements up to 8.5 mm minimum distance C 08 Order No. BA 92-20-256 Issue 01.03.08...
  • Page 44 Description Order No. ------------------------------------------------------------------------------------------------------------------------------------------------------------------ Simplified working Positioning tube PPR2 Ø 30 mm 80-40-513 Noise damping or Noise damping tube PSR2 protect against dropping welding spatters Ø 35 mm 82-40-016 Tripod with 3-point rest PSI2 ISO nails 100 to 300 mm length 92-40-043 welding elements from 40 mm length...
  • Page 45 Description Order No. ------------------------------------------------------------------------------------------------------------------------------------------------------------------ Accurate positioning Centering device complete PZV2 in welding templates with cylinder pin, centering pot and chuck extension Ø 20 mm 92-40-111 Ø 26 mm 92-40-117 Ø 30 mm 92-40-119 PZV2 Centering tube Ø 20 mm 80-40-082 Ø...
  • Page 46 Description Order No. ------------------------------------------------------------------------------------------------------------------------------------------------------------------ Welding elements Distance ring 16 mm 92-40-010 40 to 56 mm length Foot ring Foot Ø 6 mm 80-40-049 Ø 6 mm with hard tip 80-40-076 Pitch circle Ø Foot ring TK38 80-40-521 diameter 38 mm TK38 Foot 80-40-077...
  • Page 47 Description Order No. ------------------------------------------------------------------------------------------------------------------------------------------------------------------ Bending test Bending device complete BBV 92-40-042 according to including equipment to eject actual standards uptight studs, (see appendix) including a set of bushings for 3 - 8 mm Bending device 80-40-120 including equipment to eject uptight studs, without bushings Bushing for bending device...

  • Page 48: Environmentally Admissible Disposal

    Environmentally Admissible Disposal After repair of the welding gun, dispose replaced parts in an environmentally admissible way. Used materials: Steel Nonferrous metals (brass, copper) Plastics Aluminum C 08 Order No. BA 92-20-256 Issue 01.03.08...

  • Page 49: Glossary

    Glossary Arc: Electrical discharge at its own between two electrodes under sufficiently 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 Rectifier:...

  • Page 50: 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 51 Machine safety 2006/95/EC Electrical equipment designed for use within certain voltage limits 2004/108/EC EMC-Guidelines 98/37/EC Machine guideline (valid until 28.12.2009) 2006/42/EC Machine guideline (valid from 29.12.2009) 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)

  • Page 52: Further Instructions

    Further Instructions Welding elements, abbreviations, materials, standards, mechanical properties to actual standards Material Abbreviations Mechanical Stud types Material international Norm for studs characteristics name Steel (S235) Mild steel ISO 898-1 See ISO 898-1 Threaded stud copper plated 1.4301/03 Stainless steel ISO 3506-1 ISO 3506-1 Stud w elding w ith...

  • Page 53: 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 54: 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: Welding Gun Type:...

  • Page 55: Confirmation

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

  • Page 56: 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 57: Service & Support

    Service & Support C 08 Order No. BA 92-20-256 Issue 01.03.08...

  • Page 58: Index

    Index accessories ......... 42 delivery ........... 8, 13 accident prevention ......10, 23 disposal ......... 36, 48 accident prevention regulations .... 14 distance device ........28 accidents ..........24 distance ring ........46 accompanying documents ....11 DVS regulations ........28 adjustment of chuck ......
  • Page 59 headgear, protective ......23 pace maker ......9, 15, 24 heat built-up ........14 personnel ..........7 hollow parts, welding on ...... 23 pin UT ..........34 pin with internal thread IT ..... 34 pipes, welding to ......... 26 place of operation ........
  • Page 60 set-up ............ 7 welding elements, lot of ....... 27 shoes ............ 7 welding energy ........25 spare parts, ordering of ....40, 53 welding gun ........10, 49 special welding elements ..... 35 welding gun cables ......16 spring force .........
  • Page 62 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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92-20-256

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