HBS ONURFIX A 22 Operating Manual
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HBS ONURFIX A 22 Operating Manual

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A 22
Welding Gun
93-20-290
Operating Manual

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  • Page 1 A 22 Welding Gun 93-20-290 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 A 22 Operating Manual, Issue 03/2008 Order No. BA 93-20-290 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 Welding Procedure ..................31 Checking the Quality of the Weld ............... 32 5.7.1 Visual Inspection ....................32 5.7.2 Bending Test ......................33 5.7.3 Arc Blow Effect ...................... 35 Malfunctions and Corrective Actions ............36 Welding Elements ..................37 Switching off the Welding Gun ............. 40 Temporary Switching off ................

  • 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 A 22 can be connected to the HBS power units ARC 1550, IT 90, IT 130 and IT 2001. 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. Welding gun, cable length 4.85 m A 22 93-20-290 Operating Manual A 22 BA 93-20-290 A 22 Order No. BA 93-20-290 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 corresponds with protection class IP 20. It must not be used in a 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

    The connection is not secured against working itself loose! Check plug connections regularly to ensure that they are properly locked. In case of loose connection, heat may built up in the plug and may destroy the entire plug connection. Plug in the control cable of the welding gun into the appropriate connection on the power unit.

  • Page 17: Change Working Place

    Remove any rust, paint, or contaminants from the workpiece in the areas where you intend to connect the ground cables. Connect the ground clamps to the workpiece as securely as possible. Take care to ensure good contact and symmetrical connection. The welding location must...

  • 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 Ceramic The body of the welding gun consists of a sturdy two-part plastic housing (1).

  • Page 19: Installation Of Chuck And Tripod

    Installation of Chuck and Tripod Welding with Ceramic Ferrule Screw the chuck on the thread start of the welding gun and thighten it firmly with a wrench SW 14/17 (accessory). Put the stud up to the stop into the chuck. Attention: The stud must...

  • Page 20: Adjustment Of Plunging Depth (Projection)

    Put the ceramic ferrule support into the foot plate and tighten it with an Allan key 3 mm (accessory). Put on the ceramic ferrule. Adjust the foot plate until the stud can be moved in the ceramic ferrule without friction (centered). Tighten the foot plate with an Allan key 5 mm (accessory).

  • Page 21: Adjustment Of Lift

    Adjustment of Lift Screw off the cup at the rear. Now you can adjust the lift distance with an Allan key (size 8) in steps of 0.25 mm by turning it counter-clockwise. Screw on the cup. Lift distance depends on the diameter of the welding element, the work piece surface (plated sheets) and projection (see section 5.5).

  • Page 22: Adjustment Of Hydraulic Damping

    Adjustment of Hydraulic Damping A damping of the plunging movement is only required with studs above 14 mm diameter. Screw off the cup of the damper. Set the mark of the regulation screw to the required number using an Allan key (size 2).

  • Page 23: Stud Welding Procedure

    Stud Welding Procedure This chapter contains the basics of 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 stud welding unit is LIFE-THREATENING ! Threat to life by electric shock and arc...
  • 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 official 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 – The main arc burns at the set current during the welding time preselected at the power unit. The selected welding energy must match the requirements of the selected welding element. The energy of the arc melts the face of the welding element and the workpiece (see position 3).

  • 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: 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 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 verified by test...

  • Page 31: Welding Procedure

    Welding Procedure Improper operation of the stud welding unit is LIFE-THREATENING! The stud welding gun 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 accor- ding to the instructions given in the operating manual.

  • Page 32: 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 33: 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 34 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 35: 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 36: 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 37: 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 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 38 Pin UD (S) Diameter Length Chuck ceramic 20-80 mm 83-50-012 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 20-50 mm 83-50-012 20-50 mm 83-50-016 Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303 Head stud SD Diameter Length...
  • Page 39 80-30-222 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 40: Switching Off The Welding Gun

    Protect the stud 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 for environmentally correct material separation and disposal.

  • Page 41: 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 maintenance operation with the welding gun, always switch the power unit off...

  • Page 42: Regular Maintenance Operations

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

  • Page 43: Appendix

    Appendix In the appendix, there is information of interest regarding technical data, spare part lists, accessories, standards etc. Technical Data Stud Welding Gun A 22 (damped) for ARC stud welding according to current standards to 22 mm (dia. 25 mm) (Dia.

  • Page 44: Spare Parts

    Spare Parts Spare part list welding gun type A 22, ceramic (93-20-290) When ordering spare parts, please indicate order number and type of welding gun. The type is to be found at the housing. Pos. Quantity Order No. Description 88-15-914 Basic shell 88-15-915 Cover shell...
  • Page 45 Welding gun type A 22, ceramic (93-20-290) A 22 Order No. BA 93-20-290 Issue 01.03.08...
  • Page 46 Spare part list ceramic tripod 10 x 240 complete (93-40-041) for Shear connectors dia. 16 to 22 mm Position Quantity Order No. Description 80-41-028 Foot piece 80-40-110 Leg 10-240 80-40-109 Cover plate tripod 80-10-1035 Cover plate 80-90-454 Screw M6 x 30 80-90-116 Screw M6 x 16 A 22 Order No.
  • Page 47 Spare part list ceramic tripod 10 x 390 complete (93-40-074) for Shear connectors dia. 16 to 22 mm Position Quantity Order No. Description 80-41-028 Foot piece 80-40-493 Leg 10-390 80-40-109 Cover plate tripod 80-10-1035 Cover plate 80-90-454 Screw M6 x 30 80-90-116 Screw M6 x 16 A 22 Order No.
  • Page 48 Spare part list ceramic tripod 10 x 390, A-22/1“ complete (93-40-073) Position Quantity Order No. Description 88-15-824 Foot piece 80-40-493 Leg10-390 80-40-109 Cover plate tripod 80-10-1035 Cover plate 80-90-454 Screw M6 x 30 80-90-116 Screw M6 x 16 A 22 Order No. BA 93-20-290 Issue 01.03.08...

  • Page 49: Accessories

    Accessories When ordering accessories, please indicate order number and type of welding gun. Description Order No. ------------------------------------------------------------------------------------------------------------------------ Threaded studs, Chuck sleeves with internal thread and pins Ø 12 mm e 13 mm 83-50-012 Ø 16 mm e 13 mm 83-50-016 larger Ø...
  • Page 50 Description Order No. ------------------------------------------------------------------------------------------------------------------------ Concrete anchor and head stud 80-30-213 " Ø 13 mm " Ø 16 mm 80-30-219 " Ø 19 mm 80-30-219 " Ø 22 mm 80-30-222 A A 22 (ceramic) Ceramic tripod complete PSC2 Ceramic tripod complete PSC2 Ceramic tripod complete PSC2 Ceramic tripod complete PSC2 Ceramic tripod complete PSC2...

  • Page 51: Environmentally Admissible Disposal

    Environmentally Admissible Disposal After repair of the welding gun, dispose the replaced parts in an environmentally admissible way. Used materials: Steel Non ferrous metals (brass, copper) Plastics Aluminium A 22 Order No. BA 93-20-290 Issue 01.03.08...

  • Page 52: 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...

  • Page 53: 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 54 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 55: 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 56: 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 57: 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 58: Confirmation

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

  • Page 59: 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 60: Service & Support

    Service & Support A 22 Order No. BA 93-20-290 Issue 01.03.08...

  • Page 61: Index

    Index confirmation, operator sign ....7 connecting the welding gun ....15 accessories ......... 49 control cable ........18 accident prevention ......10, 24 control cable connector ....... 16 accident prevention regulations .... 14 corrective actions ........ 33 accidents ..........25 accompanying documents ....11 adjustment of lift...
  • Page 62 ground connection ....... 16 order number .... 13, 44, 46, 47, 48 guarantee claims ....10, 25, 56 ordering spare parts ...... 44, 56 guarantee clauses ....... 56 guide ............. 8 gun handle ........... 18 pace maker ......9, 15, 25 gun trigger ...........
  • Page 63 service & support ......... 60 user qualification, required ..... 7 service technician ........7 UT, pin ..........55 set-up ............ 7 shoes ............ 7 solenoid cable ........18 vapors, toxic ........14 spare parts .......... 44 visual inspection ........32 spare parts, ordering of ....
  • Page 64 A 22 Order No. BA 93-20-290 Issue 01.03.08...
  • Page 66 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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