Related Manuals for HBS IT 1002
Summary of Contents for HBS IT 1002
- Page 1 IT 1002 Stud Welding Unit Ceramic/Gas Version 93-60-1202 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 IT 1002 Operating Manual Issue 2018-01 Order No. E-BA 93-60-1202 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.
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Page 4: Table Of Contents
Connecting the Cooling Unit ................. 37 11.5 Connecting the Stud Welding Unit to the Mains Supply ........37 Welding ..................... 38 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – full or partial reproduction subject to prior approval of the manufacturer... - Page 5 Storage ..................... 66 Disposal ....................66 EC Declaration of Conformity ................67 Service & Support ....................68 Index ........................69 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – full or partial reproduction subject to prior approval of the manufacturer...
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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...
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Page 9: 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 10 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 11 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...
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Page 12: Scope Of Supply
The following ground cable is available as an accessory: No. of Part Type Order No. pieces Ground cable 5 m, 25 mm² 93-40-020 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 13: Technical Data
5 Technical Data Technical Data Stud welding unit IT 1002 – for ARC stud welding – for MARC welding with magnetic rotating arc according to current standards Gas/Automation/Process control Series/---/--- Welding range Studs dia. 2 to 14 mm, M3 to M16 (Type RD),... -
Page 14: Intended Use
‹ Please refer to the operating manual of your stud welding gun for detailed information on which welding elements may be used. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 15: 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 16: Components Of The Stud Welding Unit
The stabilizer (9) smoothes the current and passes it on to the welding sleeves. Control of the IGBT switches (7) is carried out by the control unit (6). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 17 – 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...
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Page 18: Control Panel And Display
The condition of the welding unit is monitored after switching-on. After self-test, the digital displays show the last set welding time (1) and welding current (2). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 19 – if there is a malfunction of the power element. Lights, automatic mode is switched on. Lights, shielding gas is switched on. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
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Page 20: 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 21 : 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 22 Spring pressure (arc length) (arc length) (arc length) (plunging speed) Plunging depth Plunging depth Plunging depth Plunging depth ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 23 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 24 Studs with cone-shaped front area preferably used under shielding gas. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 25 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. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
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Page 26: Marc - Welding With Magnetically Positioned Light Arc
For an optimum light arc movement, the magnetic field lines should pass radially and symmetrically through the weld gap (figure 1). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 27 Movement of a DC light arc between sleeve and plate under the influence of a radial magnetic field ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 28 This closed guidance of the magne- tic flux results in high flux densities in the weld gap. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 29 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
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Page 30: 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 31: 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 32: Checking The Stud Welding Gun
‹ 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 33: 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 34: Connecting The 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 35: 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 36: Shielding Gas Connection
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 37: Connecting The Cooling Unit
‹ 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 38: Welding
1 - Mains switch ‹ Only now switch on the stud welding unit at the mains switch (1). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 39: Determining The Welding Time And The Welding Current
©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 40 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 41 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 42 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 43 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 44 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...
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Page 45: Checking Shielding Gas Flow Rate
The flow meter displays the amount of shiel- ding gas flowing in l/min. ‹ Set the flow rate according to 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 46: Possible Settings
‹ Read and observe here Point 12.2 „Determining the Welding Time and Welding Current“. ‹ Only now set the welding current (digital display ) with the arrow keys. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 47: Adjusting The Gas Pre-Flow Time
LED is off. In this way, the gas valve remains closed during the 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 48: Library Mode
‹ If you switch the stud welding unit off and on, the stud welding unit is automatically reset to stud welding. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 49: 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 50 ‹ 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 51 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 52 ‹ 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...
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Page 53: Checking The Quality Of The Weld
– Uniformity of the weld seam, – Weld spatter and – Porosity. ‹ Carry out the visual inspection on all welding elements. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 54 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...
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Page 55: Carrying Out Bending Test
13 Check Quality of the Welded Joint 13.1.2 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 56 ‹ 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...
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Page 57: Quality Check - Marc Welding Procedure
Welding energy too high Reduce current and/or time Drop formation on the welding ele- ment Drop short-circuit ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 58: Performing Torque Test
This can falsify the determined strength. ‹ 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 59: Welding Seam Errors During Marc Welding Procedure
‹ 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 60: 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 61: Troubleshooting
Control cable broken Check control cable for Replace control cable*) Qualified specialists electrical flow*) ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 62 ‹ 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...
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Page 63: 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 64: Maintenance And Care
The inside of the stud welding unit must be cleaned at least every three months. ‹ Inform your dealer or your maintenance department. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 65: Inspection And Tests
‹ Replace any removed or damaged signs: Before opening machine disconnect mains Observe the operating manual Warning of electric shock hazard ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturers... -
Page 66: 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 67: 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 68: 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 69: Index
....6 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 70 ......11 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 72 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...