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Summary of Contents for HBS 92-10-1502B
- Page 1 CDi 1502 Stud Welding Unit 92-10-1502B 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 CDi 1502 Operating Manual Issue 2022-01 Order No. E-BA 92-10-1502B 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 Ground Cable ................32 11.3 Connecting the Stud Welding Unit to the Mains Supply ........34 ©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 ....................54 EC Declaration of Conformity ................55 Service & Support ....................56 Index ........................57 ©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 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.
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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...
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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
*) recommended welding range CDi 1502 / 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 15 (ISO leg assembly PSI with 3-point rest) not icluded in delivery *) recommended welding range CDi 1502 / 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...
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Page 16: Technical Data
Dimension L x W x H 400 x 205 x 250 mm (without handle) Weight 14 kg ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 17: 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 C 08, CA 08 and CI 03. 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 18: 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 19: Components Of The Stud Welding Unit
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 20 – 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 21: Control Panel And Display
The charging voltage is shown at the display (1). The charging voltage is set with the arrow keys ( higher (2) - lower (4)). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 22 The capacitor battery is charged with this value. In addition, the charging voltage can be modified individually by pressing 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...
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Page 23: Led Display
If one of the parameters referred to under point 8.2 “ Control Panel and Display” devi-ates from the standard value an error message will be shown on the display. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 24: 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 25 – In the ionized gap, an electric arc ignites between welding element and workpie- ce (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 26 – 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...
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Page 27: Gap Stud Welding
– The time period between ignition of the arc and solidification of the weld pool is about 1 to 2 ms. ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 28: 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 29: 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 30: 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 08, CA 08 and CI 03. -
Page 31: 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 32: Connecting The Welding Gun To The Stud Welding Unit
‹ Plug the ground cable into the corresponding socket of the stud welding unit. ‹ Press in the plug and turn it firmly clockwise (to the right). ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 33 ‹ 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...
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Page 34: Connecting The Stud Welding Unit To The Mains Supply
‹ 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 35: 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 36: Switching 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 37: Determining The Charging Voltage For The Welding Guns C 08 And Ca 08
Due to the material characteristics of Aluminium and the corresponding limitations regarding the process stabili- ty a maximum stud diameter of 6 mm is recommended. ambient temperature: 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 38: Determining The Charging Voltage For The Welding Gun Ci 03
4.8 (suitable for welding) Material of workpiece: Alloyed steel (suitable for welding) A2-50 A2-50 to be checked by test welds ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... -
Page 39: Setting The Charging Voltage
– 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 40 ‹ 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...
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Page 41: Risk Of Burns
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 42 ‹ 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 43: 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 44: 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 45 ‹ 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 46: 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 47: 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 48: Troubleshooting
Control cable broken Check control cable for Replace control Qualified specialists electrical flow*) cable*) ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 49 If the stud welding unit then still displays hot, inform the respon- sible service department ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 50 ‹ 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 51: 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 52: 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 53: 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 manufacturers... -
Page 54: 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 55: 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 56: 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 57: Index
..... 28 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer... - Page 58 ......12 ©HBS Bolzenschweiss-Systeme GmbH & Co. KG All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer...
- Page 60 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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