Related Manuals for HBS Pegasar 500 accu Insulation
Summary of Contents for HBS Pegasar 500 accu Insulation
- Page 1 Pegasar 500 accu Insulation Stud Welding Unit 92-10-0510 Operating Manual ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 2 Please keep the manual in a safe place for future reference. Transmission and duplication of this document, dissemination and notification of the contents are not permitted unless expressly approved. All rights, errors and technical amendments reserved. © HBS Bolzenschweiss-Systeme GmbH & Co. KG...
- Page 3 Dear Customer, Many thanks for buying a stud welding machine from HBS Bolzenschweiss-Syste- We at HBS wish you success at all times when working with this stud welding ma- chine. The high level of quality of our products is guaranteed by ongoing further deve- lopment in the design, equipment and accessories.
-
Page 4: Table Of Contents
Connecting the Stud Welding Gun to the Stud Welding Unit ........ 35 11.3 Connecting the Ground Cable ................36 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 5 Returns ..................... 61 EC Declaration of Conformity ................62 Service & Support ....................63 Index ........................64 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
-
Page 6: Important Safety Precautions
You will otherwise endanger yourself. This can lead to serious injury or ex- tensive material damage. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 7 ‹ Inform colleagues working in the immediate vicinity accordingly before starting work. ‹ Ensure that an approved fire extinguisher is available at the work- place. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 8 This will help to prolong the service life of your stud welding machine. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 9 A short circuit between the battery contacts can cause burns or a fire. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
-
Page 10: Symbols And Terms Used
This symbol prompts you to wear ear protection. A loud bang > 90 dB (A) can occur during the welding process. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 11 Have a suitable fire extinguisher for the working area ready before starting work. Work instruction – List ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 12 Workpiece: Components such as sheet metal or tubes to which the welding elements are to be fastened ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
-
Page 13: Scope Of Supply
‹ Report any transport damage or missing components immediately to the delive- ring shipping agent or the dealer (address, see page 2). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 14: Accessories
Toolbag 88-24-466 Danger due to unsuitable batteries Only use the battery recommended by HBS in this stud welding unit. Unsuitable batteries can lead to injuries and to signifi cant damage to proper- Danger due to unsuitable charging units Only charge the battery with a charging unit recommended by HBS! Unsuitable charging units can cause fi... - Page 15 3-point rest) not included in delivery *) recommended welding range Pegasar 500 accu Insulation / welding gun with this equipment ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
-
Page 16: Technical Data
5 Technical Data Technical Data Stud welding unit Pegasar 500 accu Insulation for stud welding with tip ignition (capacitor discharge welding) in accordance with the applicable standards Welding range CD ISO nails dia. 2 and 3 mm Cupped head pins dia. 2 and 2.7 mm... - Page 17 0 °C to 40 °C Dimension L x W x H 160 x 61 x 83 mm Weight Approx. 1.3 kg ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
-
Page 18: Intended Use
Any other use will result in the desired strength of the welded joint being reduced. This stud welding unit can only be used with following HBS components: – welding gun C 06-3 with ground cable (Order No. 92-40-154) and –... -
Page 19: Warranty
The same applies likewise to installed units from our sub- suppliers. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 20: Components Of The Stud Welding Unit
8 Components of the Stud Welding Unit Components of the Stud Welding Unit The Pegasar 500 accu insulation is ideal for use on construction sites: Protection from damage: – Recessed operation panel – Recessed and slanted connection sockets Sturdy configuration: –... -
Page 21: Main Assemblies
Likewise, the charge level of the battery does not affect the welding result. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 22 – Connection voltage – Mains fuse – Power consumption – Cooling method – Protection class – Date ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
-
Page 23: Operation Panel And Display
= set program value Library value For the Pegasar 500 accu Insulation, HBS makes available an extensive library function for various combinations of materials. The values of the library function are called library values. The library value is a rec- ommendation from HBS that was determined through test welds in accordance with DIN 14555. - Page 24 (3)) after selecting the respective diameter, welding is performed according to the welding parameters of the library value. Program value In addition to the library function, the Pegasar 500 accu Insulation also features a program function. The values of the program function are called program values. Program values are determined through test welds and differ from the library value.
-
Page 25: Indicator Lights
The internal temperature of the stud welding unit is too high. Yellow The stud welding unit is switched on and ready for weld- ing. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 26: Mains Switch
The battery is not charged in this switch position. Use the "On/Off" button to switch on the stud welding unit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 27: Securing The Battery
For longer transport distances, shipment and sto- rage with inserted battery, we recommend using the transport protection. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 28: Welding Process
4). – The pressure spring continues to push the welding element into the weld pool. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 29 – In the ionized gap, a light arc ignites between welding element and workpiece (see figure, position 2). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 30 – Time between ignition of the arc and solidification of the weld pool is about 3 ms. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
-
Page 31: Preparing Workplace And Welding Process
‹ Ensure that there is no equipment or apparatus in the working area that could be damaged by weld spatter. ‹ Remove if necessary. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 32: Preparing Surfaces
This ensures a high strength of the welded joints. ‹ Weld the welding element only to a flat surface. ‹ Ask your application consultant at HBS about welded joints on tubes and riffle plates (see page 2). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG... -
Page 33: Checking The Stud Welding Gun
‹ Always check the operating manual of your stud welding gun to see whether it may be used with this stud welding unit. This stud welding unit can only be used with the HBS stud welding guns C 06-3 and CI 03. -
Page 34: Connection
This can cause the cables to come out of the plug sockets. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 35: Removing The Transport Protection
‹ Therefore always check that the plug connector is firmly inserted. This prevents a poor contact and hence overheating of the plug connectors. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 36: Connecting The Ground Cable
‹ Attach the ground clamp to the workpiece as tightly as possible. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 37: Welding
Strong electromagnetic fields are produced in the vicinity of the stud welding unit during welding. These fields may impair the function of the heart pace- makers. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 38: Switching On The Stud Welding Unit
‹ Only now may you switch on the stud welding unit with the "On/Off" button (2). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 39 The battery is then secured in the battery compartment and the con- tacts closed. Danger due to unsuitable batteries ‹ Only use the battery recommended by HBS in this stud welding unit (see chapter 4 Accessories). Unsuitable batteries can lead to injuries and to significant damage to proper- ©HBS Bolzenschweiss-Systeme GmbH &...
-
Page 40: Determining The Charging Voltage
©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 41 Middle position, pushbutton to be checked by test welds The library value (LED in middle position) is the value recommended by HBS. ‹ Perform test welds to check the recommended voltage value. We recommend the „CD stud welding with contact” welding procedure from a minimum workpiece thickness of 0.6 mm for mild steel and of 0.8 mm for...
-
Page 42: Setting The Charging Voltage
12 Welding Voltage values of the LED For documentation purposes, you can ascertain the voltage values as follows: Welding element Charging voltage of Pegasar 500 accu Insulation in volts 12.3 Setting the Charging Voltage ‹ Use pushbuttons to set the charging voltage. -
Page 43: Performing The Welding Process
Such work may only be carried out by welding specialists. ‹ Do not carry out such work if you have not been specially trained for it. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 44 ‹ Only now should you press the button of the welding gun. The welding process is started. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 45 (determined through test welds) ‹ Check your welding result. ‹ If necessary, change the charging voltage with pushbuttons ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 46 ‹ Now check the quality of the welded joint before inserting a new welding element and repeating the welding process. ‹ Work in accordance with the following point 13. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
-
Page 47: Charging The Battery
To indicate the battery is charging the LED´s will light from left to right. Only when the right LED lights, the battery is fully charged. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 48 ‹ Pull the battery to the back and out of the battery compart- ment. Danger due to unsuitable chargers ‹ Only charge the battery with a charging unit recommended by HBS! (see chapter 4 Accessories). Unsuitable charging units can cause fires! ‹...
-
Page 49: Automatic Shutdown
- 5°C to + 50°C Relative humidity: 0% - 50% at + 40°C 0% - 90% at + 20°C ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 50: Checking The Quality Of The Weld
Weld pool came out on one side Welding gun put at an angle Put welding gun vertically to the workpiece ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 51: Carrying Out Bending Test
13 Checking the Quality of the Weld 13.2 Carrying out 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. -
Page 52: Optimisation Of Welding Parameters
‹ As first step, conduct the tests outlined under points 13.1 and 13.2. ‹ As second step optimise the welding parameters of your stud welding unit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 53: Troubleshooting
Press welding gun Trained personnel display in sleep mode start button or place stud welding gun on workpiece ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 54 ‹ Please use the form „Service & Support“ in the annex to send in the stud welding unit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
-
Page 55: Shutting Down
A short circuit between the battery contacts can cause burns or a fire. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 56: Maintenance And Care
‹ Do not use solvents for cleaning. These can damage the surface of your stud welding unit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 57: Inspection And Tests
‹ First unplug the mains plug. ‹ Switch off the stud welding unit at the mains switch. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 58 The battery is then secured in the battery compartment and the contacts closed. Danger due to unsuitable batteries ‹ Only use the battery recommended by HBS in this stud welding unit (see chapter 4 Accessories). Unsuitable batteries can lead to injuries and to significant damage to proper- ©HBS Bolzenschweiss-Systeme GmbH &...
-
Page 59: Storage
Relative humidity: 0 % - 50 % at +40 °C 0 % - 90 % at +20 °C ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 60 ‹ Insert the battery with the correct orientation (left: double groove, right: groove). ‹ Insert the battery and lock the battery compartment. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
-
Page 61: Disposal
‹ Send in the stud welding unit without the battery. Due to its nature, the Accu 150 battery is classified as dangerous goods. ‹ Observe the HBS leaflet on safe handling of batteries when shipping used batteries. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG... -
Page 62: Ec Declaration Of Conformity
EC Declaration of Conformity EC Declaration of Conformity in Accordance with Directive 2006/42/EC, Annex II 1 A (Original EC Declaration of Conformity) Herewith the manufacturer HBS Bolzenschweiss-Systeme GmbH & Co. KG Felix-Wankel-Strasse 18 P.O. Box 13 46 85221 Dachau GERMANY... -
Page 63: Service & Support
Service & Support Service & Support With the return please attach a copy of the filled out form together with the repair number given by HBS! Repairs without repair number will not be processed. Repair number (given by HBS) Company:... -
Page 64: Index
..... . 31 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 65 ......12 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 66 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – full or partial reproduction subject to prior approval of the manufacturer...
- Page 68 HBS Bolzenschweiss-Systeme GmbH & Co. KG Felix-Wankel-Strasse 18 • 85221 DACHAU • GERMANY Phone +49 8131 511-0 • Fax +49 8131 511-100 • E-mail international@hbs-info.com www.hbs-info.com...