HBS Visar 1200 Operating Manual

Stud welding unit ceramic /gas version

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Visar 1200

Stud Welding Unit

Ceramic /Gas Version

93-60-0120

Operating Manual

Table of Contents

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Summary of Contents for HBS Visar 1200

Page 1 Visar 1200 Stud Welding Unit Ceramic /Gas Version 93-60-0120 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 +49 8131 511-100 E-mail international@hbs-info.com www.hbs-info.com Visar 1200 Operating Manual Issue 2023-01 Order No. E-BA 93-60-0120 Translation of the Original Operating Manual 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.
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 ........ 45 11.2 Connecting the Shielding Gas ................46 11.3 Connecting the Ground Cable ................48 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 5 Disposal ....................121 EC Declaration of Conformity ................122 Service & Support ....................123 Index ........................124 ©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 ‹ Observe furthermore your working instructions and the accident prevention regulations. This will help to avoid health damage due to fumes and airborne parti- culates. ©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 To reduce the danger posed by electromagnetic fields, we recommend, among other things, the following rules of conduct: ‹ Lay all cables as close together as possible. For proper bundling and safeguarding of the cables, HBS offers protective tubes in various sizes. ‹ Do not position yourself between the welding cables.
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
Type Order No. Ground cable 5 m, 25 mm² 93-40-020 Toolbag 88-24-466 Shielding gas connecting hose 88-27-696 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 14 4 Accessories The following stud welding guns are recommended for Visar 1200 (ceramic appli- cation): Welding range*) M3 - M6, Ø 2 - 6 mm M6 - M10 (Type RD) / Ø 6 - 8 mm Ø 3 - 6 mm...
Page 15 *) recommended welding range Visar 1200 / 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 *) recommended welding range Visar 1200 gas version / 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 17: Technical Data
5 Technical Data Technical Data Stud welding unit Visar 1200 for ARC stud welding according to current standards Welding range dia. 2 to 16 mm, M3 to M16 dia. 14 ga to 9/16“, #4 to 5/8“ Welding material Mild steel, stainless steel, Aluminium *) *) Welding element is not standardized according to DIN EN ISO 13918, but manufactured by the manufacturer‘s discretion.
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 the HBS stud welding guns A 12, A 12-FL and A 16. The intended use also implies observance of the stud welding gun operating manual and compliance with the intervals and conditions for inspection and maintenance of the stud welding unit and the components employed.
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 Visar 1200 is ideal for use on construction sites: Operator panel with display: – Recessed to protect against damage Connection sockets (welding-current, control and ground cable, shielding gas) –...
Page 21: Main Assemblies
The welding time and welding current are fully adjustable. The type plate is located on the backside of 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 22 – Order No./Serial No. – Primary voltage – Fuse – Power consumption – Cooling class – IP code – 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
– if the stud welding unit is overheated. After a short cooling period, the work can be continued. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 24: Mains Switch
The switch for mains mode is located on the rear of the stud welding unit. 1 - 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 25: Process Control
The device is locked after a deviation occurs. After pressing the gun button for a longer period of time (> 2 seconds), the stud welding machine is again ready for welding. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 26 Experience gained from use in series production is necessary for process assessment with respect to the specific boundary conditions when using process control. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 27 1 % ... 50 % To more easily set the start parameters, a recommended value of ±10% can be defined. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 28 ‹ You have the option of entering a fixed voltage value manually. This should be determined in advance through reference welds. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 29 Voltage peak ∆ Voltage 5 ms U∆ acquisition time Defining the tolerance time Welding time tolerance 50 ms ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 30 To more easily set the properties, the system defines a reference value with the “Auto” setting automatically. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 31 In the event of NOK welds, an intervention in the production process occurs. The welding results can be recorded for subsequent evaluations. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 32: Special Commands Via Usb Interface
All command functions described in the following are not included in the scope of supply by default and must be requested separately from HBS. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 33: Documentation
Recording is ended as soon as the USB memory device is removed or the device is switched off. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 34: Oscillogram
The command for locking the device is called via the USB interface. Calling the command again cancels the lock. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 35: Welding Process
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. The standards assign this method of joining pin-shaped elements with plane workpieces to the so called ‘Arc Pressure Welding’.
Page 36 : width of about 5 : 1. All technical information and adjustment values are based on the use of welding elements which correspond with current standards. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 37 Protrusion, immersion speed Protrusion, immersion speed (plunge damper from 14 mm (plunge damper from 14 mm diameter) diameter) ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 38 Studs with cone-shaped front area and aluminium ball are preferably used with ceramic ferrule. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 39 EN ISO 13918. Welding elements with cone-shaped front area and without an aluminum ball are preferably used. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 40 To minimize pore formation, the use of shielding gas for stud diameters upwards of 8 mm is recommended. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 41: 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 42: 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 43: 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 A 12, A 12-FL and A 16.
Page 44: 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 45: Connecting The Stud Welding Gun To The Stud Welding Unit
‹ 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 46: Connecting The Shielding Gas
The valve would be destroyed. If the conduits are wrongly connected, feeding and welding malfunc- tions will occur. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 47 Do not secure the cylinder by its valve! ‹ Take measures to prevent the shielding gas cylinder from heating up. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 48: Connecting The Ground Cable
‹ Pay attention to a good contact and symmetrical connec- tion. The welding point should be in the middle between the two ground clamps. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 49: Connecting A Usb Stick
‹ Check that the stud welding unit is switched off. ‹ Only now insert the plug into the plug socket. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 50: Welding
These fields can adversely affect the function of medical devices as well as the course of a pregnancy. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 51: Switching On The Stud Welding Unit
‹ When switching on the stud welding unit, do not set the welding gun on the workpiece. The stud welding unit will otherwise not switch to “Ready”. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 53 Information and recommendations on this can be found in DIN EN ISO 14555. We recommend the “drawn arc stud welding with shielding gas” welding procedure. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 54 Information and recommendations on this can be found in DVS 0902. We recommend the “drawn arc stud welding with shielding gas” welding procedure. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 55 Information and recommendations on this can be found in DIN EN ISO 14555. Shielding gas according to DIN EN ISO 14175-M21, see chapter 9 “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 56 Information and recommendations on this can be found in DVS 0902. Shielding gas according to DIN EN ISO 14175-I1/HBS recommendation, see chapter 9 “Welding Process”; for better welding results, we recommend changing the polarity of the welding voltage by reversing the welding current and ground cables.
Page 57 When welding without weld pool protection, the welding time should be se- lected as short as possible. The welding energy is selected through the welding time alone. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 58: Setting Welding Parameters
– Updates and special programs for creating QM documents – Changing system settings (workpiece counter, measuring unit, language) ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 59 < < < E X I T display. ‹ Press a knob to confirm this selection. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 60: Basic Settings
Time and Welding Current". ‹ Only now should you set the required welding time ( ) with the knob. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 61 ‹ To do so, turn a knob to the right ("on") or the left ("off"). ‹ Press a knob to confirm this selec- Gas on/off tion. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 62 The "GAS" option now 1200A 1500ms appears in the display. G A S S Y N M E N U ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 63: Syn Setting - "Stud Welding Mode Synergy
‹ To do so, turn a knob to the right. ‹ Press a knob to confirm this selec- Back Stud type Stud material Diameter tion. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 64 ‹ Select the stud material, the welding range and the stud material in accordance with your welding task. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 65 ‹ To do so, proceed as described in Section 12.3.1 Basic settings, sub-sec- tion The "GAS" option – shielding gas settings. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 66 – Stud and/or workpiece surface: Bare Galvanised *) Nickel-plated *) Copper-plated *) Oiled Primered Galvanised surface ≤ 7 µm ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 67 ‹ To do so, turn a knob to the right. ‹ Press a knob to confirm this selection. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 68 PA position (flat position) No ceramic Welding without ceramic ferrule Use the arrow to get to the next selection window. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 69 ‹ Select “Process control – On”. ‹ Press a pushbutton/knob to confirm this selection. ‹ Now define your tolerances: ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 70 Auto 0.2 mΩ ... 25.5 mΩ Resistance tolerance 10 mΩ ‹ Define the resistance of the circuit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 71 From 0 °C / 32 °F To 800 °C / 1472 °F Use the arrow to get to the next selection window. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 73 16Mo3 A2-50 (1.4301) 1.4301 A4-50 (1.4571) 1.4541 - 1.4571 AlMg3 (5754), AlMg4.5, Al99.5, AlMg3, AlMg4.5, Al99 AlSi12 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 74 ‹ To do so, read the operating manual of your welding gun. Use the arrow to get to the Teach-in mode. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 75 The welding system is now set to the welding gun. Use the arrow to end the Teach-in mode. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 77 ‹ Proceed as described in the following. ‹ Switch on process control only after doing this. You thereby prevent unwanted deviations. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 78: The "Menu" Option - Program And System Management
In the display, the note “New” appears next to the “USB menu” symbol: Save job ‹ Press a knob to confirm this selection. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 79 ‹ You can assign a name with up to eight characters for your settings. Use the arrow to end the “Save job” mode. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 80 “Edit” menu without making changes. Back Save job ‹ Press a knob to confirm this selection. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 81 ‹ Turn the knob all the way to the right until “Exit” appears in the display to end the “Save job” menu. Exit Save job ‹ Press a knob to confirm this selection. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 82 Please set 2.0 mm 3.0 mm Back Use the arrow to end the “Menu” option. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 83 ‹ Press a knob to confirm the selection. Deleted programs cannot be recovered! Use the arrow to end the “Delete job” mode. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 84 An entry window now appears. Use the knob (turn to the left or right) to select num- bers and letters to name the program. ‹ Press a knob to confirm this selection. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 85 ‹ You can assign a name with up to eight characters for your program. Use the arrow to end the “Save on USB” mode. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 86 ‹ Turn the knob all the way to the right until “Exit” appears in the display to end the “Save on USB” menu. Save on USB Exit ‹ Press a knob to confirm this selection. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 87 ‹ Turn a knob to the right and select the program that you would like to load from the USB stick. ‹ Press a knob to confirm this selection. Load from USB TEST2 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 88 Optionally, special programs can be loaded which lock the knobs to prevent uninten- tional changes to the welding parameters. ‹ Ask your application consultant for more information. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 89 Please follow the instructions in the display for updates: Update / Special program _P000000 Updates and additional programs will be sent and explained by HBS as needed. Use the arrow to end the “Update / Special program” mode. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG...
Page 90 Load job Settings menu The following selection options are now available: Standardi- Back Counter Unit Language sation ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 91 The following selection options are now available: Day counter for main screen Reset Back day counter overall counter for main screen ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 92 The overall counter now appears in the display. G A S S Y N M E N U ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 93 The day counter now shows “0” in the display. G A S S Y N M E N U ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 94 Back Save job Load job Settings menu The following settings are now based on the set standardisation. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 95 Load job Settings menu The diameter specifications in the following menus now appear in the set measuring unit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 96 Back Delete Save job Load job Settings menu The menu now appears in the set language. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 97: The "Adv" Option - Adjusting Process Parameters
Lift Protrusion Back Pre current Process control Fine adjustment (penetration depth) Spring force ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 98 ‹ Turn a knob to the right to the respective symbol. ‹ Press a knob to confirm this selection. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 99 A lift that is set too large can also cause the auxiliary electric arc to extin- guish. ‹ Therefore, check the lift of the welding gun before adjusting the pre cur- rent. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 100 (penetration depth) Spring force ‹ Press a knob to confirm this selection. ‹ Now define your tolerances. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 101 Voltage peak ∆ Voltage 5 ms U∆ acquisition time ‹ Define the tolerances for the transient voltage. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 102 Auto 0.2 mΩ ... 25.5 mΩ Resistance tolerance 10 mΩ ‹ Define the resistance of the circuit. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 104 Only after pressing the gun button for a longer period of time (> 2 seconds) is the stud welding machine again ready for welding. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 106 With process control switched on and the “Documentation” USB command activated via a USB memory device, all fine adjustments made using this function are also recorded. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 107: Performing The Welding Process
– Where there is limited mobility on electrically conductive parts – In damp, wet or hot rooms. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 108 ‹ Observe furthermore your working instructions and the accident preventi- on regulations. Glowing hot weld and liquid spatter occur during welding. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 109 The gun head becomes very hot during the welding process. The same applies to the welded element and the workpiece. ‹ Wear your proper protective clothing. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 110: Sleep Mode
– actuating the welding gun start button or – placing the stud welding gun on 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 111: Checking The Quality Of The Weld
Decrease current and/or time many spatters Plunging speed too high Adjust plunging depth and/or Welding element too short damping factor ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 112: 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 113 ‹ Grind off hardened workpiece surfaces (e.g. roll hardening). ‹ Check the piston of the welding gun for ease of movement. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 114: Optimisation Of Welding Parameters
‹ If necessary re-adjust the lift and spring pressure. ‹ Refer here to the operating manual of your welding gun. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 115: Blowing Effect And Remedies
(on welding guns with external welding cable) by turning the welding gun about its vertical axis. Blowing effect Cause Remedy ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 116: Troubleshooting
Welding sequence too Stud welding unit resets Let switched on stud Trained personnel fast automatically welding unit cool down ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 117 ‹ 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 118: Shutting Down
‹ Protect the stud welding unit and its components against the ingress of liquids and foreign matter. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 119: 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 120: Inspection And Tests
IEC 60974-4 “Periodic inspection and testing”. Please contact your customer advisor for further information. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 121: Storage
‹ Dispose of the stud welding unit only via the manufacturer or a specia- list disposal company. ‹ Never dispose of the stud welding unit in the domestic refuse. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
Page 122: 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 123: 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 128 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...

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93-60-0120

HBS Visar 1200 Operating Manual

1 Important Safety Precautions

2 Symbols and Terms Used

3 Scope of Supply

4 Accessories

5 Technical Data

6 Intended Use

7 Warranty

8 Components of the Stud Welding Unit

9 Welding Process

10 Preparing Workplace and Welding Process

11 Connection

12 Welding

13 Checking the Quality of the Weld

14 Troubleshooting

15 Shutting down

16 Maintenance and Care

17 Storage

18 Disposal

EC Declaration of Conformity

Service & Support

Index

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