HBS ONURFIX IT 2002 Operating Manual
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HBS ONURFIX IT 2002 Operating Manual

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IT 2002
Power Unit
93-66-2201
Operating Manual

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  • Page 1 IT 2002 Power Unit 93-66-2201 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 2002 Operating Manual, Issue 06/2008 Order No. BA 93-66-2201 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 ..............31 5.6.1 Adjusting the Welding Time ................... 32 5.6.2 Adjusting the Welding Current ................32 5.6.3 Library Mode ......................33 5.6.4 Conversion Current Curve ..................33 Welding Procedure ..................34 Checking the Quality of the Weld ............... 35 5.8.1 Visual Inspection ....................
  • Page 7 Glossary ..................58 Regulations and Standards ............59 Further Instructions ............... 61 Guarantee Clauses ................ 62 Confirmation .................. 63 Feedback ..................64 Service & Support ................. 65 Index ....................66 IT 2002 Order No. BA 93-66-2201 Issue 01.06.08...
  • Page 8 viii IT 2002 Order No. BA 93-66-2201 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 16, A 22 and A 25 can be connected to the HBS power unit IT 2002. 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 specific 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. When receiving the delivery, check everything for damages and completeness.

  • 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 2002 93-66-2201 Operating Manual IT 2002 BA 93-66-2201 IT 2002 Order No BA 93-66-2201 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: 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 21: 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 2002 Order No BA 93-66-2201 Issue 01.06.08...

  • 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 o cial bodies immediately.

  • Page 25: 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 26 – 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 27: 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 28: 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 29: 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 30: Determination Of Welding Parameters

    Determination of Welding Parameters The adjustment of welding parameters on the power unit (e.g. welding time) or on the welding gun (e.g. lift) depends amongst others on – material of the welding element – diameter of the welding element – material of the workpiece The guidelines should be veri ed by test welding on the actual material and be changed if necessary.

  • Page 31: 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. IT 2002 Order No BA 93-66-2201 Issue 01.06.08...

  • Page 32: Adjusting The Welding Time

    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 33: Library Mode

    5.6.3 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 1‘4 (1‘4 means the set welding current and welding time for stud diameter of 1/4“).

  • Page 34: Welding Procedure

    Welding Procedure Improper operation of the stud welding unit is LIFE-THREATENING! The stud welding unit must only be opera- ted 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 35: 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 36: 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. The welded joint is stressed by bending in a non-defined way.
  • Page 37 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 38: Arc Blow Effect

    5.8.3 Arc Blow Effect A so called arc blow e ect can occur with unproportionally distributed ground connections 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 39: 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 40: 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 41: 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 42: Open The Power Unit

    Open the Power Unit Open the power unit only if you are sufficiently qualified in repairing electrical equipment. Remove the 9 screws of the cover and remove the crane hook. Remove the 5 screws of the side plate and remove the ground conductor from the inside of the side plate.

  • Page 43: Appendix

    Appendix In the appendix, there is information of interest regarding technical data, spare part lists, accessories, standards, etc. Technical Data Power unit IT 2002 for ARC stud welding according to current standards Welding range #4 to 1'’, dia. 14 ga to 1'’ (M3 to M24, dia.

  • Page 44: Spare Parts

    Country module USA complete 80-11-573 Recessed grip P2 80-10-0949 Ring screw turnable 80-10-1142 Label mat white 80-10-1141 Label mat black 80-11-754 HBS Logo small 37 x 28 80-50-406 Mains cable 88-12-889 Safety label IT 2002 Order No BA 93-66-2201 Issue 01.06.08...
  • Page 45 Power unit type IT 2002 (93-66-2201) IT 2002 Order No BA 93-66-2201 Issue 01.06.08...
  • Page 46 Basic set-up complete IT 2002 (88-16-268) Pos. Quantity Order No. Description 88-16-194 Support complete 80-10-1020 O-ring, 16,00 x 6,00 80-11-806 Air wheel Ø = 260 mm 88-12-233 Distance washer internal 88-12-234 Washer 80-90-370 Screw M6 x 16 80-11-916 Guide roll 80-90-203 Screw M6 x 12 80-90-198...
  • Page 47 Basic set-up complete IT 2002 (88-16-268) IT 2002 Order No BA 93-66-2201 Issue 01.06.08...
  • Page 48 Front assembly complete IT 2002 (88-16-269023) Pos. Quantity Order No. Description 88-16-464 Front wall printed 88-13-164 Front lm 80-50-0071 Mains switch 80-90-378 Screw M4 x 14 80-90-153 Nut M4 80-80-558023 Electronic board IT processor 88-11-784 Distance sleeve 80-11-415 Distance stud 80-50-035 Mounting sleeve 88-16-865...
  • Page 49 Front assembly complete IT 2002 (88-16-269023) IT 2002 Order No BA 93-66-2201 Issue 01.06.08...
  • Page 50 Installation support complete IT 2002 (88-16-270) Pos. Quantity Order No. Description 88-16-252 Installation support complete 80-11-499 Distance stud M4 80-80-557 P.C. board IT-supply 80-90-164 Washer 4mm 80-90-195 Screw M4 x 6 88-16-333 Cooling channel complete 80-90-198 Washer 6 mm 80-90-114 Screw M6 x 10 80-50-927 Mains interference lter...
  • Page 51 80-50-640 Plug 80-50-1441 Pole connector 14 P 80-50-2641 Pole connector 26 P IT 2002 Order No BA 93-66-2201 Issue 01.06.08...
  • Page 52 Country module USA complete IT 2002 (88-17-930) Pos. Quantity Order No. Description 88-16-841 Gun connection 80-90-198 Washer 6 mm 80-90-147 Spring washer 6 mm 80-90-146 Nut M6 80-50-0709 External mounting housing 80-50-0710 Control cable sleeve 80-90-249 Screw M3 x 6 80-10-0173 Clip-on ferrite 88-16-332...
  • Page 53 Country module USA complete IT 2002 (88-17-930) IT 2002 Order No BA 93-66-2201 Issue 01.06.08...
  • Page 54 Conductor Rail complete IT 2002 (88-16-246) Pos. Quantity Order No. Description 88-16-467 Ground conductor rail KP 88-16-468 Negative conductor rail KP 80-11-674 Distance stud M6 80-90-147 Spring washer 6 mm 80-90-146 Nut M6 88-16-747 Contact block 80-90-458 Screw M10 x 35 80-90-217 Washer 10 mm 80-90-295...
  • Page 55 Setting the stud welding unit to the correct primary voltage: Insert jumper (see center of picture) to the corresponding phase (420 V, 440 V, 460 V or 480 V) Using a power unit set to an incorrect primary voltage will damage the power unit.

  • Page 56: Circuit Diagram

    Circuit Diagram IT 2002 Order No BA 93-66-2201 Issue 01.06.08...

  • Page 57: 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 2002 Order No BA 93-66-2201 Issue 01.06.08...

  • Page 58: 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 59: 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 60 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 61: 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 62: 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 63: Confirmation

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

  • Page 64: 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 65: Service & Support

    Service & Support IT 2002 Order No BA 93-66-2201 Issue 01.06.08...

  • Page 66: Index

    Index electrical voltage ..... 11, 14, 22 electromagnetic elds ......11 accident prevention ......12, 23 entire plug connection, destroying ..18 accident prevention regulations .... 16 accidents ..........24 accompanying documents ....13 fault recognition ......36, 39 airborne particles .........
  • Page 67 magnetic elds ......16, 24 recti er ..........58 mains switch ........31 recycling ..........57 maintenance ........41 regulations ........... 59 maintenance instruction repair ........... 57 for your company ......9 requirements of workplace ..... 16, 29 malfunction ........9, 39 risk of material damage ......11 markings...
  • Page 68 unauthorized use ........9 user quali cation, required ..... 9 vapors, toxic ........16 visual inspection ........35 weld, checking the quality of the ..35 welding element ........58 welding elements ......12, 30 welding elements, lot of ....... 30 welding gun ........12, 58 welding gun cables...
  • Page 70 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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