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CDM 2401Power Unit

Automatic Version92-12-2241

Operating Manual

iiii CDM 2401 Order No. BA 92-12-2241 Issue 01.03.08

CDM 2401 Operating Manual, Issue 03/2008 Order No. BA 92-12-2241

Customer Service in Germany:

HBS Bolzenschweiss-Systeme GmbH & Co. KGFelix-Wankel-Strasse 1885221 Dachau / Germany

Phone +49 (0) 8131 511-0Fax +49 (0) 8131 511-100E-mail [email protected] www.hbs-info.com

Copyright:The information contained herein may not be copied, reproduced, adapted,merged, translated or used without the prior written consent of the copyrightowner.

Adaptations, errors and technical modifications reserved without prior notice.

© HBS Bolzenschweiss-Systeme GmbH & Co. KG

iiiCDM 2401 Order No. BA 92-12-2241 Issue 01.03.08 iii

Dear customer,

Thank you very much for purchasing a power unit from HBS Bolzenschweiss-Systeme.

We from HBS wish you always successful working with this stud welding unit.

We ask you to observe the following points:

– Store the operating manual in a way that it can always be accessed by theoperator.

– Let the operator sign before starting up that he has read and completely under-stood the operating manual.

– This operating manual applies only to this stud welding unit.– Protect the stud welding unit from unauthorized use.– The stud welding unit must only be operated by trained personnel.– Let an electrician check whether the wall sockets where you want to connect the

related stud welding unit, are properly fused and grounded.– Inform our customer service in case of malfunction.– In case of accident, inform a physician and the responsible official body.

THREAT TO LIFE!Persons fitted with a pace maker must not operate the stud

welding machine.

MAGNETIC FIELDS!During stud welding, strong electro-magnetic fields aregenerated. Do not weld in the vicinity of the electrical

equipment which could be affected.

Safety instructions are a delicate subject. Anybody who handles a stud weldingunit, whether it is the welding gun or the power unit, should be familiar with them,because improper use of stud welding units can be dangerous to life.

For your own sake you should know the safety instructions for operating your HBSstud welding units inside out.

In addition to the protection of your health and the capital value of the enterprise, thesafety instructions are intended to clarify any responsibilities, which arise fromownership and operation of the equipment.

This chapter of the operating manual offers you clear and easy to understand informationfor the safe operation of your HBS stud welding unit.

iviv CDM 2401 Order No. BA 92-12-2241 Issue 01.03.08

Your power unit may differ in some details from the captions in this manual. This hasno effect on the operation of the welding machine.

Should you have questions about this manual or in case you want to order some morecopies, please provide the order number listed in the foot line.

Important reminder:

Data and information herein were collected with greatest care. Although we did our verybest to correctly update any information up to the time of delivery, there is no guaranteein respect of errors.

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.

CDM 2401 Order No. BA 92-12-2241 Issue 01.03.08 v

Table of Contents

Table of Contents

1 General ............................................................................................. 91.1 Guide to this Operating Manual .................................................................. 10

1.2 Safety Symbols .......................................................................................... 11

1.3 General Safety Instructions ........................................................................ 12

1.4 Intended Use .............................................................................................. 12

1.5 Transportation, Packaging, Storage ........................................................... 13

1.6 Accompanying Documents ........................................................................ 13

1.7 Markings ..................................................................................................... 14

2 Delivery ........................................................................................... 15

3 Starting-up ..................................................................................... 163.1 Requirements of Workplace ...................................................................... 16

3.2 Connecting the Power Unit to the Primary Power Supply .......................... 17

3.3 Connecting the Welding Gun to the Power Unit ......................................... 18

3.4 Ground Connection .................................................................................... 19

3.5 Compressed Air Connection for Automatic Stud Feeding .......................... 20

3.6 Change Working Place .............................................................................. 20

4 Function ......................................................................................... 214.1 Components of the Power Unit .................................................................. 21

4.2 Keyboard and Display ................................................................................ 22

5 Stud Welding Procedure ............................................................... 235.1 Safety Instructions ...................................................................................... 23

5.2 Functional Principle of Stud Welding .......................................................... 265.2.1 Contact Stud Welding ............................................................................................ 265.2.2 Gap Stud Welding .................................................................................................. 27

5.3 Welding Preparation ................................................................................... 28

5.4 High-Strength Welds .................................................................................. 28

5.5 Determination of Welding Parameters ....................................................... 28

5.6 Switching on the Power Unit ...................................................................... 305.6.1 Adjusting the Charging Voltage of Capacitors ......................................................... 325.6.2 Setting the Stud Feed Time (Automatic Mode) ....................................................... 33

vi CDM 2401 Order No. BA 92-12-2241 Issue 01.03.08

Table of Contents

5.6.3 Adjusting the Modes .............................................................................................. 33Program mode ....................................................................................................... 33Library mode .......................................................................................................... 34

5.6.4 Setting the Controls ............................................................................................... 355.6.5 Adjusting the Language.......................................................................................... 395.6.6 Adjusting the Lift Test (Welding Gun) ..................................................................... 395.6.7 Adjusting Service ................................................................................................... 405.6.8 Adjusting Reset ..................................................................................................... 405.6.9 Adjusting the Thyristor (Capacity Switch) ............................................................... 415.6.10 Adjusting the Gas Pre-Flow Time ........................................................................... 41

5.7 Welding Procedure .................................................................................... 425.7.1 Welding in Automatic Mode ................................................................................... 435.7.2 External Welding Start ........................................................................................... 455.7.3 Charging Monitoring (Ready) .................................................................................. 455.7.4 Contact .................................................................................................................. 465.7.5 RS232 Interface ..................................................................................................... 46

5.8 Checking the Quality of the Weld ............................................................... 475.8.1 Visual Inspection ................................................................................................... 475.8.2 Bending Test .......................................................................................................... 485.8.3 Arc Blow Effect ...................................................................................................... 50

5.9 Malfunctions and Corrective Actions .......................................................... 515.9.1 Error Codes ........................................................................................................... 52

5.10 Welding Elements ...................................................................................... 53

6 Switching off the Power Unit ........................................................ 556.1 Temporary Switching off ............................................................................. 55

6.2 Disposal ..................................................................................................... 55

7 Care and Maintenance .................................................................. 567.1 Safety Instructions ...................................................................................... 56

7.2 Regular Maintenance Operations ............................................................... 56

7.3 Tools to be Used ......................................................................................... 56

7.4 Open the Power Unit .................................................................................. 57

8 Appendix ........................................................................................ 598.1 Technical Data ............................................................................................ 59

8.2 Spare Parts ................................................................................................ 60

8.3 Transmission of Recognized Data With Microsoft® Hyper Terminal ......... 74

8.4 Environmentally Admissible Disposal ......................................................... 79

CDM 2401 Order No. BA 92-12-2241 Issue 01.03.08 vii

Table of Contents

Glossary ......................................................................................... 80

Regulations and Standards .......................................................... 81

Further Instructions ....................................................................... 83

Guarantee Clauses ........................................................................ 84

Confirmation .................................................................................. 85

Feedback ........................................................................................ 86

Service & Support ......................................................................... 87

Index ............................................................................................... 88

viii CDM 2401 Order No. BA 92-12-2241 Issue 01.03.08

Table of Contents

CDM 2401 Order No. BA 92-12-2241 Issue 01.03.08 9

1 General

Persons addressed by this operating manualThis operating manual is written for operators, personnel of the end user, and authorizedservice technicians. It provides you with all necessary information to operate the powerunit.

Required user qualificationThe power unit must only be operated by qualified personnel.

Let the power unit only be operated by persons who

– are qualified through a suitable training according to the current standards (seeappendix),

– are properly instructed,

– are physically and intellectually suitable,

– can be expected to reliably fulfill the requested job.

What else must the owner observe?Make sure that this operating manual is always in reach of the stud welding unit.Read the entire manual before operating the power unit.Strictly observe the safety instructions.Before starting up the power unit, let the operator sign the confirmation that he/she has read and fully understood the operating manual (see appendix).Do not commence stud welding until you have understood all operatingprocesses.Contact us if there are any doubts on certain operating procedures.Protect the power unit against unauthorized use.Inform our service in case of malfunction.

Based on this operating manual, a company specific work order, as well as a companyspecific maintenance instruction must be drawn up. The company specific work ordermust consider the special user conditions in your company.

Make sure that operators of the welder are provided with and wear personal protectiveequipment, e.g. protective goggles, gloves, shoes, ear protection etc.

Owners and operators make sure that the power unit is only used as directed.

During any activity such as transportation, set-up, (re-)assembly, production,maintenance etc. observe the information given in this operating manual.

1 General

10 CDM 2401 Order No. BA 92-12-2241 Issue 01.03.08

1.1 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 Power Unit" in Chapter 6"Care and Maintenance" in Chapter 7Technical Data and much more in Appendix

THREAT TO LIFE and risk of serious health and material damage incase of improper use of the power unit. Observe all notes in thisoperating manual.

Note for qualified operators (see chapter 1).

All instructions contained in this manual must also be observedby qualified operators.

The welding process and the sequence of procedures to carryout a weld are described in chapter 5.

1 General

1.1 Guide to this Operating Manual


1.2 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

Additional tips for operation and service safety

Prompt

– List

1 General

1.2 Safety Symbols


1.3 General Safety Instructions

Improper operation of the power unit is LIFE-THREATENING!Threat to life– by electric shock and arc– by toxic vapors and airborne particles– by red-hot metal spatters (fire risk)– by blow-up of explosive gases and materials– by strong magnetic fields for persons fitted with a pace makerIn addition, through improper use damage to the stud welding unitand to material can be caused. For details, see chapters 1, 3 and 5.

1.4 Intended Use

Warning: Unauthorized interference with the stud welding unitas well as unauthorized alteration of the stud welding unit areprohibited and result in complete cancellation of any guaranteeand liability claims against HBS.

Operation of the power unit is only allowed with HBS weldingguns, this clause is also part of ”use as directed”.

The power unit is intended to weld welding elements according to actual standards (seechapter 5 and appendix). Any other use is regarded as not used as directed. Themanufacturer is not liable for damages resulting from the stud welding unit not used asdirected. Any risk is carried by the user.

The power unit is designed according to specific standards and accident preventionregulations. Basics are European Union guidelines and in Germany valid standards.Please note that in your country additional standards and safety conditions (especiallyrules for accident prevention) may differ from the standards mentioned in this operatingmanual. The power unit was manufactured to the latest developments in technology andis regarded as safe to operate (place of operation see section 8.1).

The welding guns C 08, CA 08, PAH-1 and the welding head KAH 412 can be connectedto the HBS power unit CDM 2401. For details please contact the HBS customer service(address see page ii).

Check in any case the operating manual of the HBS welding gun whether thispower unit can be used.

Observing the operating manual of the used welding gun is also part of the ”use asdirected”.

1 General

1.3 General Safety Instructions


1.5 Transportation, Packaging, Storage

HBS delivers products in a specific transport package.

Save the undamaged packing. Ship and transport the device only in its originalpacking.

Right before delivery, the power unit is once again checked for proper functioning anda control mark is attached. When receiving the delivery, check everything for damagesand completeness. If damages occurred during transportation or components aremissing, inform the manufacturer or the haulier immediately (see page ii).

Proper functioning of the power unit can only be checked before starting-up by visualinspection (visible damage).

The following items are to be observed if the power unit is not to be put into operationimmediately after delivery.

– The power unit must be stored in a secure place– The power unit must be protected against humidity, dust, metallic dirt.

– Storage temperature: - 5 °C to + 50 °C

– Relative humidity: 0% to 50% at +40 °C0% to 90% at +20 °C

If you resell the power unit, please provide us with the name and postal addressof the new owner so that we can advise them of any changes to the operatingmanual.

1.6 Accompanying Documents

In addition to this operating manual, you must observe the operating manual of thewelding gun as well as applicable accident prevention and safety instructions.

1 General

1.5 Transportation, Packaging, Storage


1.7 Markings

There are various markings and safety symbols attached to your power unit (seesection 8.1).

Make sure that all markings remain clearly visible.

Type plateThe type plate contains the following data:

Manufacturer

Type

Order No./Serial No.

Primary voltage

Fuse

Power consumption

Cooling class

Protection class

Date

Safety symbols

Replace illegible or damaged markings

Before opening machine disconnect mains

Observe operating manual

Warning of dangerous electrical voltage

Secure the following safety symbols in the area of welding place:

1 General

1.7 Markings


2 Delivery

The basic equipment of your power unit contains the following components:

No. of pieces Part Type Order No.

1 Power unit CDM 2401 92-12-22411 Operating Manual CDM 2401 BA 92-12-2241

2 Delivery


3 Starting-up

In this chapter you learn what to observe during setting-up and starting-up of the powerunit.

3.1 Requirements of Workplace

Vapors and airborne particles may occur during stud weldingoperations. Especially with surface treated materials, toxicvapors may be produced.

Ensure that a fume extraction is available and that the room is adequatelyventilated according to accident prevention regulations.If possible, do not weld in rooms which are lower than 3 meters.Special regulations apply for confined rooms, according to accident preventionregulations of the official bodies (see appendix).Weld only in adequate distance from combustible articles or liquids.Before you start welding, remove any combustible articles or liquids in vicinity ofthe workplace.Make sure that a fire extinguisher is within reach.Never weld in rooms exposed to risk of explosion.Do not set-up the product in the vicinity of any apparatus or equipment which issensitive to welding spatters.Do not set-up the product in the vicinity of any apparatus or equipment which issensitive to magnetic fields.

Set-up the power unit:

– on a stable, clean and level surface– so that no-one is influenced or injured by welding spatters– so that all cables and primary lines are protected from being damaged– so that nobody will trip or fall over the cables or connection lines.

Ensure that air is able to circulate freely through the housing.

If heat is built-up inside the housing caused by bad air circulati-on, the stud welding unit will be seriously damaged.

3 Starting-up

3.1 Requirements of Workplace


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 weldingunit during welding. Such fields may affect the proper function of apace maker. Thus persons equipped with a pace maker must notoperate the stud welding unit and must not stay in its vicinity duringwelding.

During the actual welding process, you must expect red-hot weldingspatters, possibly liquid spatters, a flash, and a loud bang > 90 dB (A).Alert any colleagues who are occupied in the vicinity of the welder.Wear your personal protective equipment according to actualstandards (see appendix).

3.2 Connecting the Power Unit to the Primary Power Supply

Compare the primary voltage specified on the type plate with the voltage providedby your primary power supply. The type plate is located on the backside of thepower unit.

Never connect the welder to a power supply with a voltagedifferent from the voltage indicated on the type plate.

Check the current consumption specified on the type plate with the fuse rating ofyour primary power supply.

Have an electrician check whether the outlet to which you want to connect thepower unit is correctly grounded.

Switch off the power unit.

Insert the primary plug into the checked outlet.

3 Starting-up

3.2 Connecting the Power Unit to the Primary Power Supply


3.3 Connecting the Welding Gun to the Power Unit

Switch off the power unit. In this way, you avoid any risk ofelectrical shock.

Plug the welding cable of the welding gun into the socket of the power unit.Press-in the plug and twist firmly clockwise.

The connection is not secured against working itself loose!Check the plug connections regularly to ensure that they areproperly locked. In case of loose connection, heat may build upin the plug and may destroy the entire plug connection.

Plug the control cable in the connector of the power unit.

Twist the retaining nut of the control cable connector clockwise to secure theconnection.

The welding gun cables must not be coiled during welding.Coiled cables work as a coil and may negatively affect thewelding result. Before welding, lay out the cables lengthwise.

Fix the cables. Strong magnetic fields occur during welding which may cause amovement of the cables. This may cause a slackness of the connections.

3 Starting-up

3.3 Connecting the Welding Gun to the Power Unit


3.4 Ground Connection

Plug the ground cable in the connector of the power unit.

Press in the plug and twist firmly clockwise.

The connection is not secured against working itself loose!Check the plug connections regularly to ensure that they areproperly locked. In case of loose connection, heat may build upin the plug and may destroy the entire plug connection.

Remove any rust, paint, or contaminants from the workpiece in the areas whereyou 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 lie directly between the two groundclamps.

3 Starting-up

3.4 Ground Connection


3.5 Compressed Air Connection for Automatic Stud Feeding

If you use the automatic stud feeding unit, put the air hose of the compressed airsupply (6 bar, 800 l/min) into the feeder unit VBZ-3.

Connect the compressed air outlet of the feeding unit to the compressed air inletof the power unit.

An operating pressure of max. 6 bars can be set with thepressure reduction valve of the feeding unit. The filter unitcleans and drains the compressed air.

Rear view

3.6 Change Working Place

Switch off the power unit. In this way, you avoid any risk ofelectrical shock.

When you move your workplace, disconnect the welding gun and the groundcables from the power unit. Proceed in reversed sequence as described insection 3.2, 3.3, 3.4 and 3.5.

After changing the workplace, check the welding gun and the ground cables forpossible damage or missing components.

3 Starting-up

3.5 Compressed Air Connection for Automatic Stud Feeding


4 Function

In this chapter you learn more about the design of the power unit and how to use thevarious setting options.

4.1 Components of the Power Unit

The power unit consists of the following main assemblies

- Charging unit (1) - Control (2)

- Welding capacitors (3) - Welding thyristor (4)

Mains alternating current is converted into direct current in the rectifier (1). Weldingcapacitors (3) are charged to the adjusted voltage. The capacitors store the energywhich is required for the welding process. The total energy is set by the user via thecharging voltage.

The electronic switch (4) releases the charging voltage in the right time.

The charging process as well as the welding process are controlled by the controlunit (2).

The negative pole of the capacitor is connected to the welding gun.

The positive pole is mostly connected to the work piece via the vice grips.

4 Function

4.1 Components of the Power Unit


4.2 Keyboard and Display

The terminal is the interface with the user. You are provided with information about thestate of the power unit via the display. You can program the power unit with the keysaccording to your requirements.

How to use displays and keys is described in section 5.6.

4 Function

4.2 Keyboard and Display


5 Stud Welding Procedure

This chapter contains the basics of stud welding, how you must actually proceed, andwhat must be observed. You learn to select correct welding parameters and whichwelding elements can be used.

5.1 Safety Instructions

Improper operation of the power unit is LIFE-THREATENING!Threat to life– by electric shock and arc– by toxic vapors and airborne particles– by red-hot metal spatters (fire risk)– by blow-up of explosive gases and materials– during welding of hollow parts– by strong magnetic fields to persons fitted with a pace maker

THREAT TO LIFE by electrical shock and arcDuring the actual stud welding process, do not touch the weldingelements, chuck, or retaining nut nor any electrically conductive partsin their vicinity. These are all electrically life.Step onto an insulating mat, if you have to weld under the followingconditions:– in confined rooms with electrically conductive walls– under confined conditions between or on electrically conductive

parts– with restricted freedom of movement on electrically conductive

parts– in wet or hot areasWhen operating the stud welding unit, you must not wear any metallicjewellery incl. wrist watches, especially on hands. Remove anyelectrically conductive or electro-magnetically sensitive parts fromyour body before you start welding. In this way, you avoid the risk ofdamage by electric shock or influence of electromagnetic fields.




THREAT TO LIFE by toxic vapors and airborne particlesToxic vapors and airborne particles may occur during stud weldingoperations, especially with surface treated materials.Ensure that a fume extraction is available that the room is adequatelyventilated according to accident prevention regulations.If possible, do not weld in rooms which are lower than 3 meters.Special regulations apply for confined rooms according to accidentprevention regulations of the official bodies of your country (seeappendix).

THREAT TO LIFE by red-hot metal spatters (fire risk)Make sure that a fire extinguisher is within reach.Do not wear clothes, which are contaminated with combustiblematerials like oil, grease, kerosene etc. during welding.Always wear your personal protective equipment such as:– protective gloves to current standards (see appendix),– safety goggles with a window providing protection class 2 to

current standards (see appendix),– non-combustible clothes– ear protection to current standards (see appendix),– a protective apron over your clothes,– a protective headgear when welding overhead.Before starting to weld, remove all combustible articles and liquids invicinity of the workplace.Weld only in sufficient distance from combustible articles or liquids.choose a safety distance where there is no risk to injury from weldingspatters!

THREAT TO LIFE by blow-up of explosive gases and materialsNever weld in rooms exposed to danger by explosion.Special know-how is required when welding hollow parts which– are combustible or support combustion,– can emit toxic gases, vapors, or airborne particles,– can explode.Never execute such operations, if you do not have such special know-how.

Observe the regulations for accident prevention and standardswhich apply to the use of your stud welding unit (see appendix).The official Professional Association of your country willprovide you with further information.Please note that in your country additional standards and safetyconditions (especially rules for accident prevention) may differfrom the standards mentioned in this operating manual.




THREAT TO LIFE to persons fitted with a pace maker

Strong electro-magnetic fields occur in the vicinity of the stud weldingunit during welding. Such fields may affect the proper function of apace maker. Thus persons equipped with a pace maker must notoperate the stud welding unit and must not stay in its vicinity duringwelding.

During the actual welding process, you must expect red-hot weldingspatters, possibly liquid spatters, a flash, and a loud bang > 90 dB (A).Alert any colleagues who are occupied in the vicinity of the welder.Wear your personal protective equipment according to actualstandards (see appendix).

MAGNETIC FIELDS!During stud welding, strong magnetic fields are present. Do notweld in the vicinity of electrical systems and machines whichcould be affected.


In case of any accidents whatsoever, advise a physician, your supervisor, andthe official bodies immediately.




5.2 Functional Principle of Stud Welding

Stud welding with tip ignition is divided into gap stud welding and contact stud welding.

5.2.1 Contact Stud Welding

– The welding gun is placed onto the workpiece (figure 5.2.1, position 1). The weldingelement which projects above the welding gun support legs, is pushed backtensioning a pressure spring.

– After positioning the welding gun against the workpiece, the operator triggers thewelding gun button and starts the welding process; thus the current circuit is closed.

– The capacitors of the power unit are discharged. Because of the high dischargecurrent, the ignition tip evaporates explosion-like. The air gap between weldingelement and workpiece is ionized (see figure 5.2.1, position 2), an arc is produced.

– The arc melts the face of the welding element together with an area of the workpieceof about the same dimension (see figure 5.2.1, position 3).

– Caused by the pressure spring, the welding element moves to the workpiece with aspeed of 0,5 to 1 m/s. The adjusted spring force controls the plunging speed of thewelding element.

– Higher plunging speed leads to shortened arc time and consequently to lowerwelding energy with identical voltage setting.

– The arc is cut as soon as the welding element touches the workpiece.– Now the capacitors are short-circuited and the rest of the energy drains off (see figure

5.2.1, position 4).– The pressure spring continues to push the welding element into the weld pool.– The weld pool solidifies and the welding element is physically connected to the

workpiece.– The time period between ignition of the arc and solidification of the weld pool is about

3 ms.

With high plunging speed of the welding element, the air gapcloses after vaporization of the ignition tip faster, thus the arctime becomes shorter. With rapidly oxidizing materials like e.g.aluminum, the arc must only burn a very short time.

– The use of contact welding for rapidly oxidizing materials like aluminum andaluminum alloys is not recommended because the arcing period with contactwelding is longer than with gap stud welding.




5.2.2 Gap Stud Welding

– The solenoid, which is integrated into the welding gun, lifts the welding elementfrom the workpiece (see figure 5.2.2, position 1) to the adjusted value ”lift” abovethe workpiece and tensions a pressure spring (see figure 5.2.2, position 2).

– As soon as the welding piston has reached the upper stop, the current to the solenoidis cut. Simultaneously, the welding thyristor is triggered and releases the currentflow to the welding element.

– The capacitors of the power unit are discharged. Because of the high dischargecurrent, the ignition tip evaporates explosion-like. The air gap between weldingelement and workpiece is ionized (see figure 5.2.2, position 3), an arc is produced.

– The arc melts the face of the welding element together with an area of the workpieceof about the same dimension (see figure 5.2.2, position 4).

– The welding element is moved by the pressure spring to the workpiece with a speedof 0,5 to 1,5 m/s. The adjusted spring force and the preset lift distance controls theplunging speed of the welding element.

– Higher plunging speed leads to shortened arc time and consequently to lowerwelding energy with identical voltage setting.

– The arc is cut as soon as the welding element touches the workpiece.– Now the capacitors are short-circuited and the rest of the energy drains off (see figure

5.2.2, position 5).– The pressure spring continues to push the welding element into the weld pool.– The weld pool solidifies and the welding element is physically connected to the

workpiece.– The time period between ignition of the arc and solidification of the weld pool is about

1 to 2 ms.

With high plunging speed of the welding element, the air gapcloses after vaporization of the ignition tip faster, thus the arctime becomes shorter. With rapidly oxidizing materials like e.g.aluminum, the arc must only burn a very short time.




5.3 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 electricalshocks.

Check the chuck for proper seat (see operating manual of according weldinggun).

Before welding, make sure that the bellows are checked for damage and properseat.

5.4 High-Strength Welds

The following must be removed both from the weld zone and the ground clampconnection areas:

– paint, oil and any other impurities,

– rust,

– non-conductive coatings from surface treated workpieces.

Weld to smooth and flat surfaces only.

For welding to pipes or punched plates consult our responsibleapplication manager (address of customer service see page ii).

5.5 Determination of Welding Parameters

The adjustment of welding parameters on the power unit (e.g. charging voltage via energycontroller) or on the welding gun (e.g. spring force) 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 welding on the actual material and be changedif necessary. For an assessment of welding results, see section 5.8 and 5.9.


5.3 Welding Preparation


Data given in the following table are only guidelines. They mustbe verified by trial welds on the actual material according toactual standards and DVS guidelines (see appendix). Beforeyou use another lot of welding elements, carry out some trialwelds to verify the parameter setting.

Material ofwelding elements

C 0899.000 µF 33.000 µF Spring force Spring force Lift

PT, UT IT Thyristor 1 + 2 Thyristor 1 (scaling) (scaling) (mm)

S235 / St37 (4.8) M3, 3 mm -- 1/8" #6-32 60 100 6 2 1S235 / St37 (4.8) M4, 4 mm -- 5/32" #8-32 80 120 6 2 1S235 / St37 (4.8) M5, 5 mm 5 mm, M3 3/16" #10-32 100 160 6 2 1,6S235 / St37 (4.8) M6, 6 mm 6 mm, M4 1/4" 1/4-20 130 210 6 6 1,6S235 / St37 (4.8) M8, 7,1 mm 7,1 mm, M5 5/16" 5/16-18 170 -- 9 6 2S235 / St37 (4.8) M10, -- -- 3/8" 3/8-16" 220 1) 2) -- 9 6 2

S235 M3, 3 mm -- 1/8" #6-32 80 120 6 6 1S235 M4, 4 mm -- 5/32" #8-32 120 150 6 6 1S235 M5, 5 mm 5 mm, M3 3/16" #10-32 170 210 3 6 1S235 M6, 6 mm 6 mm, M4 1/4" 1/4-20 210 -- 3 6 1S235 M8, 7,1 mm 7,1 mm, M5 5/16" 5/16-18 -- 1) -- -- -- --

1.4301, 1.4303 M3, 3 mm -- 1/8" #6-32 60 70 6 6 1,41.4301, 1.4303 M4, 4 mm -- 5/32" #8-32 70 110 6 6 1,41.4301, 1.4303 M5, 5 mm 5 mm, M3 3/16" #10-32 90 150 6 6 1,61.4301, 1.4303 M6, 6 mm 6 mm, M4 1/4" 1/4-20 130 220 6 6 21.4301, 1.4303 M8, 7,1 mm 7,1 mm, M5 5/16" 5/16-18 170 -- 11 6 21.4301, 1.4303 M10, -- -- 3/8" 3/8-16" 220 1) 2) -- 11 6 2

CuZn37 M3, 3 mm -- 1/8" #6-32 60 90 6 6 1CuZn37 M4, 4 mm -- 5/32" #8-32 70 130 6 6 1CuZn37 M5, 5 mm -- 3/16" #10-32 100 180 9 -- --CuZn37 M6, 6 mm -- 1/4" 1/4-20 150 -- 9 -- --CuZn37 M8, 7,1 mm -- 5/16" 5/16-18 220 2) -- 9 -- --

AlMg3 M3, 3 mm -- 1/8" #6-32 60 90 6 9 1AlMg3 M4, 4 mm -- 5/32" #8-32 80 125 6 9 1,4AlMg3 M5, 5 mm 5 mm, M3 3/16" #10-32 100 160 6 9 2AlMg3 M6, 6 mm 6 mm, M4 1/4" 1/4-20 140 220 11 9 2,4AlMg3 M8, 7,1 mm 7,1 mm, M5 5/16" 5/16-18 210 2) -- -- 9 3

Gun parameters

CA 08

Material of workpiece: Aluminum

(metric)

Material of workpiece: Mild steel, shiny S235 / St37.3k (4.8) weldable

Material of workpiece: Steel galvanized S235

Material of workpiece: Cr-Ni stainless steel 1.4301, 1.4303

Material of workpiece: Brass CuZn37

Diameter of welding elements EnergyCDM 2401

Charging voltage (V)(imperial)

1) power unit with higher capacity recommended2) to be checked by trials

Further notes on– welding elements– prestress at installation (tie load) and torque– material combinationssee appendix and operating manual of the according weldinggun.


5.5 Determination of Welding Parameters


5.6 Switching on the Power Unit

Improper operation of the stud welding unit isLIFE-THREATENING!First read the safety instructions in chapters 1, 3 and 5.

Insert the primary plug of the power unit into an appropriate socket.

Switch on the power unit with the mains switch.

The condition of the welding machine is permanently monitored after switching on. Thefollowing parameters are recorded:

– Deviation of common charging time

– Unit temperature

– Thyristor malfunction

If one of the above mentionned parameters deviates fron the nominal value, an errormessage is displayed on the operator terminal, see section fault recognition andcorrective actions.




The LCD display shows the charging voltage set the last time.

SymbolsTogether with the display, the symbols provide a quick overview over the condition of thepower unit. If a certain condition is present, the display shows two black bars below therelated symbol. The symbols mean:

CHARGE, capacitors are charged

READY, power unit is ready for welding

CONTACT, there is electrical contact between stud and work piece

TRIGGER, welding gun button is triggered

SOLENOID, a drawn-arc welding gun is connected

LCD Display2 x 20 characters, height 9 mm,with background illumination and automatic contrast control

KeysENTER, confirmation of selected function

ARROW, marks the selected program item

PLUS, increases the selected parameter

MINUS, decreases the selected parameter




LED'sIf you are working with process sequence control, see section 5.6.4, then the LED’sinform whether the PAF value is inside the tolerance range of the reference or not.

Green value inside of adjusted tolerance range

Red value out of adjusted tolerance range

Basic settingsYou can set the machine according to your requirements. Call-up the main menu withthe Enter key . The following menu items are available:

– Automatic Setting air pressure time for VBZ and tappet

– Mode Selection between program and library mode

– Control Activation of process sequence control

– Language Selection of language

– Welding gun Lift test of drawn-arc welding gun

– Service Time and date setting

– Reset Reset to HBS standard settings

– Thyristor Capacity switch (CDM 2401/CDM 3201/SCD 3201))

– Gas Setting of gas pre-flow time (SCD 3201)

Basically, you select a menu item with the arrow key and then you open it withthe enter key . Confirmation of settings and quitting the menu item is also carriedout with the enter key .

5.6.1 Adjusting the Charging Voltage of Capacitors

Refer to the table in section 5.5 for the required charging voltage matching yourwelding job.

Select the menu item charging voltage with the arrow key .

Set the charging voltage (LCD display) with the two arrow keys( ) on the display.

P5 > 1 5 0 V




5.6.2 Setting the Stud Feed Time (Automatic Mode)

In automatic mode, you can set the blow time (stud feeding time) of VBZ and the piston.The blow time can be set between 50 ms and 5,000 ms.

Press the arrow key until the sign „>“ is dislayed in front of „Automatic“.

⇒ use the enter key > Au t o ma t i c Mo d eCo n t r o l L a n g u a g eto open the menu item „Automatic“.

With the keys or > Au t o ma t i c OnBl o w t i me : x x x mS you can switch on or

off the automatic function.

Now use the arrow key to Au t o ma t i c On> Bl o w t i me : x x x mSselect the menu item ‘blow time’.

Set the blow time with the keys or .

5.6.3 Adjusting the Modes

You can select between program and library mode.

Program modeIn program mode, 8 storage places are available. You can assign and call-up anindividual charging voltage to each place.

Program selection

Press the arrow key until

the sign ">" appears to the left of "P x" > P5 1 5 0 V

⇒ select the program with or

Progam number: 1 to 8

Select charging voltage


the sign ">" appears to the left of "xxx V". P5 > 1 5 0 V

⇒ increase charging voltage with

⇒ decrease charging voltage with

Charging voltage: 50 V to 220 V




Library modeIn library mode, you can call-up charging voltages related to stud diameter and studmaterial. If necessary, you can modify the charging voltage. Preset values are onlyguidelines. They apply for identical materials of stud and work piece.

Selection of stud diameter

Press the arrow key until the

sign ">" is displayed to the left of "M x" > M5 Al Mg 3 1 3 0 V

⇒ increase diameter with

⇒ decrease diameter with

Diameters: M3, M4, M5, M6, M8

Selection of material

Press the arrow key

until the sign ">" points to the material M5 > Al Mg 3 1 3 0 V

⇒ select material with or

Materials:

S235 mild steel S235

S235 + Zn galvanized steel (S235 + zinc < 25 µm)

1.4301 stainless steel 1.4301, 1.4303

AlMg3 aluminum AlMg3; AlMgSi0,5

CuZn37 brass (zinc < 37%)

Changing the charging voltage


the sign ">" appears to the left of "xxx V". M5 A l Mg 3 > 1 3 0 V

⇒ increase charging voltage with

⇒ decrease charging voltage with

Charging voltage: 50 V to 220 V




Setting the library mode

MaterialDiameter

M3Diameter

M4Diameter

M5Diameter

M6Diameter

M8

S235 80 V 100 V 130 V 170 V 220 V

S235 + Zn 100 V 130 V 190 V 220 V 1)

1.4301 60 V 90 V 120 V 160 V 220 V

AlMg3 70 V 100 V 130 V 160 V 1) 2)

CuZn37 60 V 70 V 120 V 180 V 1)

Preset values (guidelines) of library mode1) Only possible with use of a stronger power source2) Check by trial welds

5.6.4 Setting the Controls

Process sequence control (PAF)To be able to assess the welding procedure during welding, the present values are usedto calculate the PAF value (PAF = Process Analysis Factor). A calculation of the PAFis carried out by a special algorithm which is stored in the micro-controller. This systemof process monitoring does not require any special welding guns and/or additionalmeasurement cables.

During welding the reference part, the micro-controller determines the PAF referencevalue. This is the average value of eight subsequent welding processes.

During standard operation, the current PAF value is compared with the reference PAFvalue. If the value out of the set tolerance range, the system indicates and displays adeviation via the LED´s. You can lock the system after indication of a deviation.

You can manually enter a PAF value. This value must be determined by 8 referencewelds. In this way, the PAF value can be stored for different program sequences. It ispossible to store an individual PAF value for each stud/lot dimension and to carry outa process monitoring.




How to enable the process sequence control

Press the arrow key until the Au t o m. Mo d e> Co n t r o l L a n g u a g esign ">" appears to the left of "Control".

⇒ with the enter key open themenu item "control"

The sign ">" points to "Control".

⇒ with the key or > Co n t r o l OFF

disable "Control"

⇒ with the key or enable "Control"

The following menu items display:

> Co n t r o l ON Re f . we l d i n g or

> Co n t r o l ON Re f . I n p u t

Now you have the choice between the following options:

1. Ref. Welding:Carry out 8 reference welds. You can define a tolerance range by limiting themax. deviation of the weld values compared to the weld PAF values(sequence 1).

2. Ref. Input:The PAF value was determined through previous welds and can be stored for usewith any individual welding program.8 program places are available where you can store PAF values. In the tolerancerange you define how much the welds can deviate from the PAF value(sequence 2).

Welds for determination of the PAF value and/or manual entry of thePAF valueReference determination (sequence 1): Reference entry (sequence 2):

> Co n t r o l ON Re f . we l d i n g


At first you must select a welding program in the program mode.




With the arrow key go to the field Ref. Welding or Ref. Input.

The following menu appears:

Co n t r o l ON> Re f . we l d i n g

Co n t r o l ON> Re f . I n p u t

You determine the reference value with sequence 1, sequence 2 is manual entry.With the keys or you toggle between the menu items.

Press the enter key and the following menus are displayed:

Co n t r o l ONRa n g e > �

Co n t r o l ONREFEREN( �) > 0 0 0 0 0

Here you define the tolerance range. PAF value - manual entry

- increase tolerance range With the arrow key youchange the position.

- decrease tolerance range With and you can enter

1 - small tolerance range = the individual digits.high sensitivity Reference (z) 4 6 7 7 6

20 - large tolerance range = means that you define thelow sensitivity reference value „46776“ for the

program place 1. After the entryof the PAF value, confirm with theenter key .The following menu is againdisplayed:

Co n t r o l ONRa n g e ( �) > �

Here you define the tolerancerange.

- increase tolerance range

- decrease tolerance range

1 - small tolerance range =high sensitivity

20 - large tolerance range =low sensitivity




Press the enter key , the Press the enter key , thefollowing menu is displayed: following menu is displayed:

Co n t r o l ON> Re f . we l d i n g

Co n t r o l ON> Re f . I n p u t

With the arrow key go to the following menu:

> Co n t r o l ON Re f . we l d i n g


Press the enter key and the following menu is displayed:

Co n t r o l ON> ST OP i f RED > ON<

or

Co n t r o l ON> STOP i f RED > OFF<

With or , you toggle between the menu buttons.

Stop if Red >On< - Your unit stops automatically if the PAF value is outof the tolerance range. For release, press a key..

Stop if Red >Off< - Unit continues to weld, the LEDs show whether thewelds are inside or outside the tolerance range.

Press the enter key , the Press the enter key , thefollowing menu is displayed following menu is displayed:

Re f 84 6 7 7 6

With the setting ‘Reference With a manual entry of the PAFwelding’ you now carry out value, you switch to the program8 reference weldings. mode. Now you can carry out the

welds.

If the charging voltage or the program is changed in se-quence 1 after creation of the reference welds, the weldedreference PAF value is deleted as well as if the power unit isswitched off.New reference welds are required.

The settings of the power unit must be checked in the followingcases: change of base material, lot of welding elements, set-tings of the welding gun.The PAF value must be redetermined in the case of changedconditions.




5.6.5 Adjusting the Language

In the main menu, you can select the language which is shown in the text display.

Press the arrow key until the

sign ">" is shown to the left of "Language".Au t o m. Mo d eCo n t r o l > L a n g u a g e

⇒ with the enter key openthe menu item "Language"

⇒ select "Language" with or Se t u pL a n g u a g e > e n g l i s h

Languages: English, German

5.6.6 Adjusting the Lift Test (Welding Gun)

In this menu item, you can test the functionality of your welding gun CA 08. During thetest, the welding gun is triggered as with normal welding sequence, but the weldingcurrent is not released. A weld is not carried out.


the sign ">" appears in front of "Gun". Co n t r o l L a n g u a g e> Gu n Se r v i c e

⇒ open with enter key the menuitem "Gun"

Te s t Gu n

\ \ - - - - - - \ \

Now you can work as with standardwelding sequence, you can adjusta lift at the welding gun greaterthan zero, position the welding gunonto the work piece and trigger it.

⇒ The welding gun lifts off.




5.6.7 Adjusting Service

In this menu item, you can set date and time.

Press the arrow key Co n t r o l L a n g u a g eGu n > Se r v i c euntil the sign ">" appears in front of "Service".

⇒ with the enter key open themenu item "Service"

The following menu item is displayed: > Da t e / T i me - - - - - - - - En d

Press the enter key ,the following menu is displayed:

Da t e T i me 2 2 . 0 9 . 0 4 1 5 : 3 2 : 3 6

With the arrow key you change the position of the cursor. Use and toenter the individual numbers.

Confirm with the enter key ,the following menu is again displayed:

> Da t e / T i me - - - - - - - - En d

With the arrow key switch over to the button „End“.

5.6.8 Adjusting Reset

With “Reset” you can reset all settings of the power unit to manufacturers settings.

Attention! All your individual application settings are deleted!

Press the arrow key

until the sign ">" appears in front of "Reset".Co n t r o l L a n g u a g eSe r v i c e > Re s e t

⇒ with the enter key open themenu item "Reset"

⇒ with the enter key confirm"Reset" RESETOK X

⇒ with the arrow key cancel "Reset".




5.6.9 Adjusting the Thyristor (Capacity Switch)

With this menu item, you can select the level of welding energy via the capacity switchof the power unit.

Two levels are available (800 Ws and 2400 Ws).

Press the arrow key

until the sign ">" is displayedin front of "Thyristor".

Gu n Se r v i c eRe s e t > T h y r i s t o r

⇒ with the Enter key open menu item"Thyristor“

⇒ with or select

"Thyristor 1“ or THYRI STOR- Mo d e > Th y r i s t o r 1

"Thyristor 1 + 2“ T HYRI STOR- Mo d e > Th y r i s t o r 1 + 2

With "Thyristor 1“ you select 800 Ws, with "Thyristor 1 + 2“ 2400 Ws are available.

5.6.10 Adjusting the Gas Pre-Flow Time

Option




5.7 Welding Procedure

Improper operation of the stud welding unit isLIFE-THREATENING! The stud welding unit must only beoperated 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 workpieceaccording to the instructions given in the operating manual.

Chapter 5 contains guideline for welding parameters. The datagiven are only guidelines. They must be verified by trial weldson the actual workpiece according to actual standards and DVSregulations (see appendix).

During the actual welding process, you must expect red-hot weldingspatters, possibly liquid spatters, a flash, and a loud bang may occur> 90dB (A). Inform any collegues who are occupied in the vicinity ofthe welder about the bang.Wear always your personal protective equipment according to actualstandards (see appendix).

Insert the welding element into the chuck.

As soon as the power unit is ready for the welding process,

place the welding gun vertically against the workpiece,

push the welding gun firmly with both hands onto the workpiece until the weldinggun support (distance device) is evenly seated on the workpiece,

hold the welding gun firmly, still, and straight,

take care that you do not touch any metallic part of the welding gun,

press the trigger button of the welding gun.

This initiates the welding process.

The welding process can only be initiated, if the current circuitis closed, i.e. the welding element is in electrical contact withthe base material.

After the welding process has been completed, withdraw thewelding gun straight back from the welding element. If youremove the welding gun at an angle, the chuck will be stret-ched, this reduces its life expectancy.

You can now insert a new welding element in the chuck and repeat the welding processas described above.




5.7.1 Welding in Automatic Mode

In automatic mode the welding gun PAH-1 or the welding head KAH 412 can be usedfor welding elements from dia 3 to 8 mm.

You can manually insert the welding elements into the welding gun (semi-automatically)or you can work with a fully automatic stud feeding unit.

You can order the fully automatic stud feeding unit under the following order number:

Stud diameter Order number

VBZ-3 Ø 3 94-66-103 B

Ø 4 94-66-104 B

Ø 5 94-66-105 B

Ø 5 x-mas tree stud 94-66-153 B

Ø 6 94-66-106 B

Ø 6 x-mas tree stud 94-66-163 B

Ø 7,1 94-66-171 B

Ø 8 94-66-108 B

other Ø on request

Put the air connections of the welding gun into the related air outlet sleeves atthe front of the power unit. Note the color marking:

black = controlled air (during stud feeding time)

blue = continuous air for pushing through the stud into thechuck and working as a stop.

The power unit controls the air between these two sleeves.

With false connections, feeding and welding problems mayoccur.




Connect the air pressure supply to the air pressure intake of the power unit(6 bar/800 l/min.)

Connect the control sleeve of the feeding unit (front side) to the control sleeve ofthe power unit (rear side).

Feeding unit External control




5.7.2 External Welding Start

To integrate the power unit into a PLC stud welding system, an additional externalwelding start is provided at the rear side of the power unit (control sleeve 4 poles, Pin 2;3). The input is designed for 24 V DC control units (signal duration min. 200 ms).

External welding start:

Minimum switch currentImin = 10 mA (min. 22 V)Imax = 20 mA

A welding start can also be effected via the welding gun control plug at the front of thepower unit (Pin 3; 4).

For a welding startshort-circuit Pin 3; 4 for at least100 ms.

Power unit

5.7.3 Charging Monitoring (Ready)

A charging monitoring is provided to carry out an optimum control of the time sequenceof PLC machines. If the power unit is ready for welding, a transistor will be switched on(control sleeve, 4 poles, Pin 1; 4).

Operating voltage 24 V DCCurrent capacity max. 50 mA




5.7.4 Contact

To control the sequence of PLC machines at best, an external contact inquiry is providedbetween workpiece and welding head. If contact is signalled, the transistor is switchedon (control sleeve 3 poles, Pin 1; 3).

Operating voltage 24 V DCCurrent capacity max. 50 mA

Operation of the automatic welding head KAH 412 (see opera-ting manual).

5.7.5 RS232 Interface

Via the serial interface of the power unit, the actually recorded data can be output fora potential storage in ASCII format.

A data cable is required which can be ordered as a consumable at HBS(order no. 80-70-308).

Example for data output at serial output (e.g. Microsoft® Hyper Terminal)Output serial interface CDM units

No. Date Tim ePrg./

Libr.-ModePrg.-No.

Chargingvoltage

Capacity Mode Lock RangeRef.-PAF

PAF Status

52 20.03.2004 09:30 PRGM P1 150V 1 R ON 5 3500 3612 OK53 20.03.2004 09:31 PRGM P1 150V 1 R ON 5 3500 4100 ERR54 20.03.2004 09:32 PRGM P1 150V 1 R ON 5 3500 3246 OK

This data collection can be evaluated by a terminal program (e.g. Hyper Terminal) (seeappendix: Hyper Terminal).

Connection settings of the serial interface at a PC or notebook:

Bits per second: 19.200

Data bits: 8

Parity: none

Stop bits: 1




5.8 Checking the Quality of the Weld

You can check the quality of the weld by means of a visual inspection and a bendingtest.

See also actual standards in the appendix “Arc stud welding ofmetallic materials“, in section irregularities and correctiveactions

5.8.1 Visual Inspection

A visual inspection must be carried out with each welding element.

Condition Possible cause Corrective actionsGood welded jointLow spatters around the weld without outer flawsThe weld pool forms a collar around the flange of about 1 - 1,5 mm

- Correct parameters - None

Cold weld poolGap between flange and workpiece

- Heat input too low- Plunging speed too low- No sufficient backing of workpiece

- Increase charging voltage- Adjust plunging speed correctly- Provide sufficient backing

Hot weld poolMany spatters around the weld

- Heat input too high- Plunging speed too low

- Reduce charging voltage- Increase plunging speed

One-sided weld poolOne-sided spatter collarWeld pool came out on one side

- Arc blow effect- Unsymmetric ground connection- Welding gun put at an angle

- Take care for symmetrical ground connection- Put welding gun vertically to the workpiece

Visual Inspection




5.8.2 Bending Test

You can purchase a bending device with inserts for various diameters of the weldingelements.

The bending test serves as an easy work sample and as a check for the selected weldingparameters.

Bend the welding element with the bending device once by 30°.

Carry out the test in different directions.

The bending test is passed if a crack or a fracture of the welded zone does not occur.

Please note the instructions on fault recognition and corrective actions inchapter 5.

You don’t need to test all studs. It is sufficient to carry out studtests at random.

If the strength of the joint is inadequate, then:

check the setting of the stud welding unit

check whether the surface of welding element and base material are clean andelectrically conductive (must be free from scale, oil, paint, oxide layers)

grind off hardened workpiece surfaces (e.g. roll hardening).

Check the piston of the welding gun for ease of movement.




Type of fracture Possible cause Corrective actionsBase material buckling - Correct parameters - none

Fracture in the welding elementabove flange

- Correct parameters - none

Fracture in the weld metal - Heat input too low- Plunging speed too low- Welding element/base material combination not suitable

- Increase charging voltage- Increase plunging speed- Replace welding element or workpiece

Backside deformation - Heat input too high- Pressure too high- Contact stud welding not suitable- Workpiece too thin

- Reduce charging voltage- Reduce pressure- Use gap stud welding instead of contact stud welding- Adapt thickness of workpiece

Bending Test




5.8.3 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 atthe 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 thewelding area.

The arc blow effect is proportional to the current and can be influenced by symmetricinstallation of the ground clamps, by fitting of compensation masses, or by rotating thewelding gun around its vertical axis (applies for welding guns with external weldingcable).

Arc blow effects and some corrective actions(according to standards, see appendix)

Cause Corrective action




5.9 Malfunctions and Corrective ActionsMalfunction Possible cause Fault finding Corrective action Carried out byLight signal of primary sw itch does not light

Primary outlet defective Check primary outlet *) Replace primary outlet *) Qualif ied personnel

Mains cable broken Check mains cable *) Replace mains cable *) Qualif ied personnelNo LED display at the f ront

Fuse F4 10 AT defective Check mains fuse Replace mains fuse F4 on the front plate of the pow er unit

Instructed personnel

Leads interrupted Check leads *) Replace leads *) Qualif ied personnelNo display No ground connection Check ground connection on

w orkpieceTighten ground connection properly


Gun not connected Check w elding gun connection

Connect w elding gun properly Instructed personnel

Transition resistance (betw een stud and w orkpiece) too high

Check material surface Clean or grind material surface


Ground cable broken Check ground cable *) Replace ground cable *) Qualif ied personnel

Welding gun cable broken

Check w elding gun cable *) Replace w elding gun cable *) Qualif ied personnel

No display Defective connecting line of w elding gun

Check function of connecting line *)

Replace connecting line *) Qualif ied personnel

Welding gun trigger button defective

Check control cable for electrical f low w ith triggered start button *)

Replace w elding gun trigger button *)

Qualif ied personnel

Control cable broken Check control cable for electrical f low *)

Replace control cable *) Qualif ied personnel

Gun does not lif t, in spite of , and

No lif t adjusted Check settings of w elding gun

Modify set parameters Instructed personnel

Short circuit of solenoid circuit of the gun

Check resistance value at control cable (18 Ω to 22 Ω) betw een Pin 1 and Pin 2 *)

Replace control cable, control line, solenoid *)


Solenoid defective Check solenoid (18 Ω to 22 Ω) *)

Replace solenoid *) Qualif ied personnel

No display Solenoid circuit interrupted

Check resistance value at control cable (18 Ω to 22 Ω) betw een Pin 1 and Pin 2 *)

Replace solenoid or control line *)


Actions marked with *) must only be carried out by qualifiedelectricians!

If none of the actions is successful, please contact our servicedepartment.


5.9 Malfunctions and Corrective Actions


5.9.1 Error CodesErrornumber

Display Description Operator instructions

1 Rech. Rel. (Off) Recharge relay does not release Switch off the unit, switch on after approx. 5 minutes, if error is still present, contact HBS service

2 Rech.Rel. (ON) Recharge relay does not attract Switch off the unit, switch on after approx. 5 minutes, if error is still present, contact HBS service

3 Nom. value data Nominal value data not transferred Switch off the unit, switch on after approx. 5 minutes, if error is still present, contact HBS service

4 (#04) --- ---5 ! Not discharged ! Discharge of capacitor battery impossible Switch off the unit, switch on after approx. 5 minutes,

if error is still present, contact HBS service6 Time-Out charging Charging time of capacitor battery too long Switch off the unit, switch on after approx. 5 minutes,

if error is still present, contact HBS service7 Rech. transistor Recharging time of of capacitor battery too long Switch off the unit, switch on after approx. 5 minutes,

if error is still present, contact HBS service8 (#08) --- ---9 Charging control Charge-discharge control defective Switch off the unit, switch on after approx. 5 minutes,

if error is still present, contact HBS service10 Time-Out weld. proc. Time-out during welding process Switch off the unit, switch on after approx. 5 minutes,

if error is still present, contact HBS service11 Thyrist. def. PB Thyristor malfunction in buffer mode Switch off the unit, switch on after approx. 5 minutes,

if error is still present, contact HBS service12 Thyrist. def. weld. Thyristor defect Switch off the unit, switch on after approx. 5 minutes,

if error is still present, contact HBS service13 Key sticks Key of operating terminal sticks Trigger several times, if error is still present, contact HBS

service14 Battery voltage Voltage buffer battery main board too low Switch off the unit, switch on after approx. 5 minutes,

if error is still present, contact HBS service15 Unit temp. max Inner temperature of the power unit too high Switch off the unit, switch on after approx. 5 minutes,

if error is still present, contact HBS service16 Fan control Fan control defective Switch off the unit, switch on after approx. 5 minutes,

if error is still present, contact HBS service


5.9 Malfunctions and Corrective Actions


5.10 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 manufactured with the cold formed process have a flange and anignition tip (see actual standards in the appendix). During welding the flange preventsthe deviation of the arc to the cylindric part of the welding elements along with anincreased welding area.

We recommend the following standard welding elements (see appendix).

Use only welding elements of the same lot. Take particular carenot to mix-up different lots. Slightest variations in geometry ofthe welding elements, especially of the ignition tip, requiremodified settings of the welding process.

Threaded stud PT * Diameter Length Stud

M3 6-30 mm 82-50-003M4 6-40 mm 82-50-004M5 8-45 mm 82-50-005M6 8-55 mm 82-50-006M8 10-55 mm 82-50-008

Materials: S235 / St37.3k (4.8) / 1.4301, 1.4303 / CuZn37 / AlMg3

Pin UT * Diameter Length Stud

3 mm 6-25 mm 82-50-0034 mm 6-25 mm 82-50-0045 mm 6-40 mm 82-50-0056 mm 8-50 mm 82-50-0067,1 mm 10-55 mm 82-50-071


Pin with internal thread IT * Diameter Length Stud Internal thread(Internal thread sleeve)

5 mm 6-30 mm 82-50-905 M36 mm 8-30 mm 82-50-906 M36 mm 8-30 mm 82-50-906 M47,1 mm 10-30 mm 82-50-971 M58 mm 10-40 mm 82-50-908 M6


* from 40 mm length upwards only weldable with distance ring up to 55 mm, order no. 92-40-010.




Flat connector Dimensions Stud

6,3 82-50-050

Materials: S235 / St37.3k (4,8) / 1.4301, 1.4303 / CuZn37 / AlMg3

ISO-nails ** Diameter Length Stud

2 20-100 mm 82-50-0203 30-250 mm 82-50-030

Materials: S235 / St37.3k (4,8) / 1.4301, 1.4303

ISO-clips for nails

Ø 2

Ø 3

Materials: St2k70 galvanized / 1.4301, 1.4303

ISO-clips for nailsplastic coated

Ø 3

Material: St2k70 galvanized

We look forward to consult you with view to special welding elements and other specialmaterials.

HBS Bolzenschweiss-Systeme GmbH & Co. KGFelix-Wankel-Strasse 1885221 Dachau / GermanyPhone +49 (0) 8131 511-0Fax +49 (0) 8131 511-100E-mail [email protected]

** from 100 mm length only weldable with tripod, order no. 92-40-043.




6 Switching off the Power Unit

This chapter describes what you should observe when you switch off the power unittemporarily or completely.

6.1 Temporary Switching off

Switch off the power unit.

Unplug the control cable and the welding cable from the power unit.

Protect the power unit against ingress of fluids and foreign bodies.

6.2 Disposal

If you shut down the installation, you can return the complete power unit to HBS (foraddress see page ii).

We will take care of environmentally correct material separation and disposal.

6 Switching off the Power Unit

6.1 Temporary Switching off


7 Care and Maintenance


Let maintenance and repair operations be carried out only byqualified personnel or by your competent service technician.Before starting any repair or maintenance operation, always switchthe power unit off and disconnect the primary plug.Do not wear a wrist watch or any electrically conductive jewellery.

7.2 Regular Maintenance Operations

Clean the inner components of the power unit periodically ofdust. Use a dry washcloth or a brush. To open the power unit,proceed as described in sections 7.1, 7.3 and 7.4.

Clean the surface of the power unit with a humid washcloth and a detergent.

Do not use any solvent containing cleaning agents. Solventcontaining cleaning agents may damage the surface of thepower unit.

After a longer break of the power unit (longer than 4 weeks), werecommend to charge the welding capacitors slowly, i.e. set thecharging voltage to 50 V for 5 minutes, then to 75 V, 100 V,125 V... for 5 minutes each.

7.3 Tools to be Used

– Cross-slotted screwdriver, size 2




7.4 Open the Power Unit

Open the power unit only if you are sufficiently qualified inrepairing electrical equipment.

Remove the 14 screws of the casing (5 at each side and 4 on top).

Carefully remove the cover and disconnect the ground cable on the inside of thecover.

Now pull off the cover.




Threat to life!Check whether the welding capacitors are discharged.

Measure the voltage with a commonly used voltmeter (Measurement range directcurrent DC/–). The displayed voltage must be below 10 V.

Re-assemble the power unit in reverse sequence.

Make sure that no cables are jammed or sheared duringassembly.




8 Appendix

In the appendix, there is information of interest regarding technical data, spare part lists,accessories, standards, etc.

8.1 Technical Data

Power Unit CDM 2401 (with wide range power supply)for CD stud welding (capacitor discharge welding) according to currentstandards

Welding range #4 to 5/16” (7/16” limited),dia. 14 ga to 5/16” (dia. 3/8” limited)(M3 to M8 (M10 limited),dia. 2 to 8 mm (dia. 10 mm limited))

Welding material Mild steel, stainless steel, aluminum andbrass

Welding rate 20 to 40 studs/min(depending on application and stud dia.)

Capacitance 99,000 µF/33,000 µF*

Welding time 1 to 3 msec

Energy 2,400 Ws/800 Ws*

Charging voltage 50 to 220 V (stepless voltage regulation)

Primary power 85 to 265 V ~ wide range selection,50/60 Hz, 10 AT

Power source Capacitor

Cooling type F (temperatur controlled cooling fan)

Insulation class IP 21 (not allowed to use while raining)

Operational and storage conditions According to current standards

Dimensions L x W x H 23.62” x 9.45” x 11.02”(600 x 240 x 280 mm) without handle

Weight 57.32 lbs (26 kg)

* with change over of capacitors

8 Appendix

8.1 Technical Data


8.2 Spare Parts

Spare part list power unit type CDM 2401 (92-12-2241)When ordering spare parts, please indicate order number and type of power unit

Pos. Quantity Order No. Description

1 1 88-14-079 Bottom plate complete2 1 80-30-231 Capacitor battery 13 1 88-13-881 Terminal plate complete4 1 80-30-270 Control insert complete5 1 80-10-0207 Label mat white

6 1 80-30-232 Capacitor battery 27 1 92-50-029 Adapter control module8 1 80-80-506 P.C. board11 1 80-11-754 HBS logo small 37 x 2815 1 80-50-565 Mains cable

30 1 88-10-547 Rail connection32 1 80-70-282 Connection cable38 2 80-10-159 Cap78 4 80-10-021 Cable clamp79 1 80-70-260 Connection cable

81 1 80-70-261 Connection cable84 1 88-10-126 Cover86 1 88-10-127 Cover87 1 80-10-0208 Label mat black89 1 80-10-857 Handle A=300

96 4 80-90-150 Washer 8 mm98 4 80-90-167 Cupal washer M8102 2 80-90-202 Washer 5 mm103 10 80-90-121 Spring washer 4 mm105 2 80-90-128 Spring washer 5 mm

108 2 80-90-140 Spring washer 8 mm110 4 80-90-153 Nut M4111 4 80-11-518 Distance stud M4112 2 80-90-141 Nut M8113 2 80-90-188 Nut M5

118 8 80-90-191 Screw M4 x 8119 1 80-90-142 Screw M4 x 10120 2 80-90-166 Screw M5 x 10122 2 80-90-253 Screw M8 x 25125 19 80-90-280 Screw M4 x 10 black

8 Appendix

8.2 Spare Parts


130 5 80-90-184 Tooth lock washer A4135 4 80-90-455 Washer 4 mm139 4 80-90-289 Screw M4 x 12143 1 80-11-359 Conductor mark ground cable150 1 88-13-032 Connecting cable

151 1 88-13-038 Connecting cable155 1 88-10-710 Connection cable157 1 88-11-431 Connection cable160 1 88-11-435 Connection cable165 1 88-13-030 Connection cable

170 1 88-13-033 Connection cable175 1 88-13-031 Connection cable180 1 88-13-034 Connection cable185 1 88-13-036 Ground cable190 2 88-13-035 Ground cable

193 1 88-13-186 Ground cable195 1 88-13-187 Ground cable197 1 88-13-188 Ground cable205 1 88-13-028 Connection cable206 1 88-11-429 Connection cable

210 1 88-10-721 Connection cable211 1 88-11-436 Connection cable

8 Appendix

8.2 Spare Parts


Spare part list capacitor battery 1 CDM 2401 (80-30-231)


5 1 88-10-112 Capacitor support10 1 80-10-851 Edge protection15 1 80-56-133 Capacitor20 5 80-11-116 Grommets support25 2 80-90-191 Screw M4 x 8

30 2 80-90-121 Spring washer 4 mm35 1 88-10-113 Charging board support50 5 80-90-246 Screw 3,9 x 1653 1 88-17-400 Conductor rail front55 1 80-55-076 Thyristor

57 1 80-90-108 Screw M4 x 1260 1 80-10-177 Clamping device65 1 80-40-383 Cupal plate70 1 80-40-384 Clamping plate75 4 80-90-168 Screw M5 x 35

80 4 80-90-128 Spring washer 5 mm85 2 80-90-151 Screw M6 x 1690 2 80-90-198 Washer 6 mm95 2 80-90-245 Locking washer 6 mm100 2 80-90-239 Cupal washer M6

105 1 88-10-115 Spacer115 1 80-55-059 Diode120 4 80-11-121 Flat connection125 1 80-10-249 Flat connection130 1 80-90-248 Screw M8 x 25

135 2 80-90-150 Washer 8 mm140 1 80-90-140 Spring washer 8 mm145 1 80-90-141 Nut M8150 2 80-10-346 Distance stud159 1 88-10-888 Insulating washer

160 1 80-56-041 Capacitor165 1 80-57-332 Resistor L170 2 80-11-360 Warning sign 2,5 SL

8 Appendix

8.2 Spare Parts


Capacitor battery 1 CDM 2401 (80-30-231)

8 Appendix

8.2 Spare Parts


Spare part list capacitor battery 2 CDM 2401 (80-30-232)


5 1 88-10-112 Capacitor support10 1 80-10-851 Edge protection15 2 80-56-133 Capacitor20 5 80-11-116 Grommets support25 2 80-90-191 Screw M4 x 8

30 3 80-90-121 Spring washer 4 mm35 1 88-10-113 Charging board support50 5 80-90-246 Screw 3,9 x 1653 1 88-17-401 Conductor rail back55 1 80-55-076 Thyristor

60 1 80-10-177 Clamping device65 1 80-40-383 Cupal plate70 1 80-40-384 Clamping plate75 4 80-90-168 Screw M5 x 3580 5 80-90-128 Spring washer 5 mm

85 3 80-90-151 Screw M6 x 1687 1 80-90-363 Screw M6 x 1890 3 80-90-198 Washer 6 mm92 1 80-90-148 Washer 6 mm95 4 80-90-245 Locking washer 6 mm

100 4 80-90-239 Cupal washer M6109 1 88-10-685 Insulating part110 1 88-10-686 Clamping device diode111 3 80-90-110 Screw M4 x 8112 1 80-90-292 Screw M4 x 16

115 1 80-55-059 Diode116 1 80-90-199 Screw M5 x 12118 1 80-55-015 Rectifier120 1 80-11-121 Flat connection125 1 80-10-050 Flat connection

130 1 80-90-248 Screw M8 x 25135 2 80-90-150 Washer 8 mm140 1 80-90-140 Spring washer 8 mm145 1 80-90-141 Nut M8150 2 80-10-346 Distance stud

155 1 80-90-153 Nut M4156 1 80-90-164 Washer 4 mm157 1 80-90-181 Cupal washer M5170 2 80-11-360 Warning sign 2,5 SL

8 Appendix

8.2 Spare Parts


Capacitor battery 2 CDM 2401 (80-30-232)

8 Appendix

8.2 Spare Parts


Spare part list control insert complete CDM 2401 (80-30-270)


8 1 88-10-117 Control casing11 2 80-10-280 Distance stud13 1 80-80-428 P.C. board14 2 80-90-190 Spring washer 3 mm15 2 80-90-137 Screw M3 x 8

16 2 80-90-263 Nut M319 1 88-10-119 Board support21 3 80-10-785 Adhesive clip22 1 80-10-842 Cable mounting23 15 80-90-121 Spring washer 4 mm

24 2 80-90-153 Nut M426 3 80-90-191 Screw M4 x 829 1 80-80-468 P.C. board distribution31 6 80-90-261 Screw M4 x 1033 1 80-80-507 P.C. board

36 1 80-80-516 P.C. board, equipped39 1 80-80-446 P.C. board, equipped41 1 80-80-508 P.C. board42 1 80-50-955 Battery44 11 80-11-401 Cable mounting

48 4 80-11-518 Distance stud49 1 80-80-506 P.C. board52 2 80-10-346 Distance stud56 2 80-90-108 Screw M4 x 1258 1 88-10-118 Front plate

61 1 88-10-120 Protective window64 1 80-11-160 Front film68 4 80-11-415 Distance stud71 1 80-80-430 P.C. board74 4 80-11-486 Distance stud M3

78 1 80-50-050 Primary switch81 1 80-10-837 Dust protection cap86 1 80-50-047 Fuse element88 1 80-50-028 Fine-wire fuse 10 AT91 3 80-11-400 Distance stud M6

95 4 80-11-111 Cage nut M4103 2 80-11-359 Conductor mark ground cable110 4 80-90-137 Screw M3 x 8115 1 88-13-029 Connection cable116 4 80-10-0171 Clip-on ferrite

8 Appendix

8.2 Spare Parts


Control insert complete CDM 2401 (80-30-270)

8 Appendix

8.2 Spare Parts


Spare part list adaptive control module CDM 2401 (92-50-029)


5 1 88-10-110 Valve carrier10 2 80-90-191 Screw M4 x 815 4 80-90-121 Spring washer 4 mm20 1 80-10-188 Solenoid valve25 1 80-10-189 Utensil socket

30 1.1 m 80-50-300 Control cable35 1 80-10-024 Nipple40 1 80-10-139 Connector male45 1 80-10-143 Connector female50 2 80-90-262 Screw M4 x 30

55 2 80-90-164 Washer 4 mm70 1 88-13-014 Connection cable80 1 88-12-988 Connection cable85 1 80-80-570 P.C. board95 1.3 m 80-10-182 Plastic hose

100 2 80-10-171 Fast coupling105 2 80-10-140 Distance stud107 2 80-10-656 O-ring 4 x 1,5 mm110 2 80-10-013 Connector female115 2 80-10-332 Adhesive tap

120 1 80-50-680 Plug 4 pin125 1 80-11-401 Cable mounting130 1 80-50-084 Control cable connector132 1 80-50-172 Control cable connector

8 Appendix

8.2 Spare Parts


Adaptive control module CDM 2401 (92-50-029)

8 Appendix

8.2 Spare Parts


Spare part list module connection plate CDM 2401 (88-13-881)


1 1 88-10-104 Terminal plate21 2 80-50-035 Mounting sleeve23 1 80-30-193 Control cable sleeve25 1 80-11-440 Cable screwing27 1 80-11-441 Lock nut

31 2 80-10-576 Flat connection33 2 80-56-215 Capacitor noise suppression35 2 80-90-176 Screw M3 x 1037 1 80-11-359 Conductor mark ground cable

8 Appendix

8.2 Spare Parts


Module connection plate CDM 2401 (88-13-881)

8 Appendix

8.2 Spare Parts


Spare part list module bottom plate complete CDM 2401 (88-14-079)


9 1 88-10-123 Bottom plate14 5 80-10-203 Support legs16 1 80-08-832 Resistor support18 1 80-50-775 Mains interference filter23 1 80-57-037 Resistor 30R, 70W

28 1 88-10-106 Rear wall29 4 80-11-087 Cap48 2 80-50-766 Fan53 2 88-10-105 Fan guard56 2 80-11-408 Stainless steel mesh

62 1 80-10-0128 Solder tag M464 2 80-10-0199 Flat connection M495 10 80-11-111 Cage nut M4101 11 80-90-164 Washer 4 mm102 2 80-90-202 Washer 5 mm

103 13 80-90-121 Spring washer 4 mm105 3 80-90-128 Spring washer 5 mm110 8 80-90-153 Nut M4113 2 80-90-188 Nut M5114 2 80-90-178 Screw M4 x 12

115 3 80-90-265 Screw M4 x 20116 2 80-90-199 Screw M5 x 12117 8 80-90-261 Screw M4 x 10118 2 80-90-191 Screw M4 x 8125 2 80-90-280 Screw M4 x 10 black

130 5 80-90-184 Tooth washer A4131 1 80-90-177 Tooth washer A5135 8 80-90-252 Blind rivet 4 x 16143 4 80-11-359 Conductor mark ground cable146 1 80-11-357 Conductor mark N

147 1 80-11-358 Conductor mark PE148 1 80-11-356 Conductor mark L1

8 Appendix

8.2 Spare Parts


Module bottom plate complete CDM 2401 (88-14-079)

8 Appendix

8.2 Spare Parts


8.3 Transmission of Recognized Data With Microsoft® Hyper Terminal

Switch on the controlling function of the output voltage (see section 5.6.4).

Any data can individually be processed in the window Microsoft® Hyper Terminal.

Link the data cable (HBS order no. 80-70-308) to the serial sleeve of the powerunit and to the serial sleeve (com1 or com2) of a PC/Laptop.

Hyper Terminal call-up :Start

ProgramsAccessories

CommunicationHyper Terminal

8 Appendix



Name the connection (e.g. the company name or a date - however without dots)

Select a symbol (any symbol)

Confirm with OK

Define the interface (com1 or com2 at the PC)

Confirm with OK

8 Appendix



Define the connection settings

Transmission rate: (Bits per second)

– CDM units 19200

– IT 1000 units 115200

Confirm with OK

8 Appendix



Do not forget to save data

8 Appendix



Give a file name

Confirm with start

8 Appendix



8.4 Environmentally Admissible Disposal

After repair of the power unit, dispose replaced parts in an environmentallyadmissible way.

Used materials: - Steel

- Nonferrous metals (brass, copper)

- Plastics

- Aluminum

8 Appendix

8.4 Environmentally Admissible Disposal


Glossary

Arc: Electrical discharge at its own between two electrodesunder 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 electricalcharge

Power unit: Device to provide electrical energy for stud welding

Rectifier: Electric component transforming alternating currentinto direct current

Stud feeder: Device for the automatic stud feeding of welding ele-ments

Stud welding unit: Power unit inclusive welding gun

Thyristor: Electronic component, contactless switch, which willlet the current only pass through if a control pulse isgiven to the gate (additional electrode)

Welding element: A component, like a stud, bolt, pin, which is welded tothe work piece

Welding gun: Device to weld welding elements

Welding parameters: Various settings on the gun as well as on the powerunit. For example: duration and strength of currentduring welding process, charging voltage, spring forceof the welding gun.

Work piece: A component, like a sheet, tube, etc. to which thewelding element is fastened

Glossary


Regulations and Standards

The regulations and standards are recommendations and don`t purport to becompletely.

Standards, regulations Description

Stud welding (fundamentals)

DIN EN ISO 13918 Welding - Studs and ceramic ferrules for arcstud welding

DIN EN ISO 14555 Welding - Arc stud welding of metallic materials

DIN EN 1418 Welding personnel - Approval testing of weldingoperators for fusion welding and resistance weldsetters for fully mechanized and automaticwelding of metallic materials

DVS 0901 Stud welding method for metals - Survey

DVS 0902 Arc stud welding

DVS 0903 Capacitor discharge welding with tip ignition

DVS 0904 Tips - Arc stud welding

DVS 2927 Resistor projection welding and Arc welding ofone-sided thick plastics coated thin metalsheets

Stud welding (general)

DIN EN ISO 4063 Welding and allied processes - Nomenclature ofprocesses and reference numbers

DIN ISO 857-1 Welding and allied processes - Vocabulary -Part 1: Metal welding processes

DIN EN ISO 14175 Welding consumables - Shielding gases forfusion welding and allied processes

DIN EN 764-1 Pressure equipment - Part 1: Terminology -Pressure, temperature, volume, nominal width

DIN EN 6947 Welds - Working positions - Definitions ofangles of slope and rotation

DIN 1910 Welding



Machine safety

73/23/EWG Electrical equipment designed for use withincertain voltage limits

2004/108/EG EMC-Guidelines

98/37/EG Machine guidelines

DIN EN 60204-1 Safety of machinery - Electrical equipment ofmachines - Part 1: General requirements

DIN EN 60529 Degrees of protection provided by enclosures (IPcode)

DIN EN 60974-1 Arc welding equipment - Part 1: Welding powersources

DIN EN 60974-10 Electromagnetic compatibility (EMC); Arcwelding equipment - Part 10: Requirements

Personal safety and accident prevention

DIN EN ISO 20345 Personal protective equipment:Safety footwear

DIN EN 12477 Protective gloves for welders

DIN EN 166 Personal eye-protection - Specifications

DIN EN 352-1 Hearing protectors - General requirements -Part 1: Ear-muffs

BGV A1 Safety rules „Principles of prevention“

BGV A3 Accident prevention regulation „Electricalequipment and operating material“

BGV B3 Safety rules “Noise”

BGV B11 Safety rules “EMC”

BGV D1 Safety rules - welding, cutting and similarprocesses

Please note that in your country additional standards and safetyconditions (especially rules for accident prevention) may differfrom the standards mentioned in this operating manual.



Further Instructions

Welding elements, abbreviations, materials, standards, mechanicalproperties to actual standards

Abbreviationsfor studs Material

Materialinternational

nameNorm

Mechanicalcharacteristics

Steel (S235) 4.81)

copper platedMild steel ISO 898-1 See ISO 898-1

Stainless steelAISI 304/305

Brass

EN AW-Al99,5

Aluminum99,5

EN 573-3 Rm ≥ 100 N/mm2

AluminumAlMg3

EN AW-AlMg3

EN 12301-2 Rm ≥ 230 N/mm2

1.4301/03(A2-50)

ISO 3506-1 ISO 3506-1

CuZn37(Ms63)

EN 12166 Rm ≥ 370 N/mm2

ITStud w ith internal

thread

Stud types

Threaded stud PT

Pin(Unthreaded stud)

UTStud w elding w ithcapacitor

discharge (TS)

Further materials on request 1) weldable

Prestress at installation (tie load) and torque

Threadedstud

Prestress at installation

(kN)

Torque(Nm)


(kN)

Torque(Nm)


(kN)

Torque(Nm)


(kN)

Torque(Nm)

M 3 1,1 0,8 0,7 0,5 0,5 0,4 0,8 0,6M 4 1,8 1,8 1,1 1,1 1,0 0,9 1,4 1,3M 5 3,0 3,6 1,9 2,3 1,6 1,9 2,3 2,7M 6 4,3 6,1 2,7 3,8 2,2 3,1 3,2 4,5M 8 8,0 15,0 4,9 9,5 4,0 7,5 6,0 11,0M 10 13,0 30,0 7,8 19,0

Steel (S235) 4.81)

µ = 0,18Rp0,2 = 340 N/mm2

1.4301/03 (A2-50)µ = 0,18

Rp0,2 = 210 N/mm2

AlMg3 (F23)µ = 0,18

Rp0,2 = 170 N/mm2

CuZn37 (Ms63)µ = 0,18

Rp0,2 = 250 N/mm2

Values correspond with actual standards 1) weldableAll given values are leads for minimum tensile strength and minimum torque of a weld without permanent deformationof parts to be joined. Parts to be joined must have sufficient wall thickness. Values apply for cold rolled threaded studswith standard thread without surface protection and without thread lubrication. Throughout the entire stud length, atleast the stressed cross section must be present. Values apply for indicated yield strengths.

Material combinationsaccording to the actual standards (select stud material in a way that material of thesame kind is welded).

ISO/TR 15608Groups 1 - 6, 11.1

ISO/TR 15608 Groups 1 - 6, 11.1 and galvanized and metal plated steel sheets, max. coating thickness

25 µm

ISO/TR 15608

Group 8

Copper and unleaded

copper alloys,e.g. CuZn37 (CW508L)

ISO/TR 15608

Groups 21 and 22

Steel (S235) 4.81) a b a b --

1.4301/1.4303 a b a b --

CuZn37 b b b a --

EN AW-Al99,5 -- -- -- -- b

EN AW-AlMg3 -- -- -- -- a

-- non weldablea well suited fo r any application, e.g. power transmissionb suitable, limitations with power transmission

Base material

Stud material

Exemplification o f welding suitability:

Weldability tests of other material combinations upon request. 1) weldable

Further Instructions


Guarantee Clauses

Please refer to the current “General Terms and Conditions” for the guarantee clauses.

We are not liable for malfunctions which are caused by

– normal wear,

– improper use,

– non-observing the operating manual,

– transport damages.

Any guarantee claim will be cancelled if repair operations are carried out by unauthorizedpersons.


Please fill in the serial number:

Serial number automatic welding head: .................................................

Serial number power unit: .................................................

Serial number welding gun: .................................................

Serial number stud feeder: .................................................

Please indicate the serial numbers in case of enquiries or when ordering spare parts.

Guarantee Clauses


Confirmation

Herewith I confirm that I have read and understand the present operating manualcompletely.

Date Name

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

________________ ___________________________________

Confirmation


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 ____________________________________________

Feedback


Service & Support

Service & Support


Index

Aaccident prevention ........................12, 24accident prevention regulations ............ 16accidents ............................................ 25accompanying documents ................... 13adaptive control module ....................... 69air connections .................................... 43airborne particles ................................. 16arc ................................... 26, 27, 53, 80arc blow effect ..................................... 50arrow key ......................................22, 32articles, combustible ........................... 16automatic mode .................................. 33automatic mode, welding ..................... 43automatic welding head ....................... 80automatic welding head KAH 412 ........ 46

Bbang ....................................... 17, 25, 42bending device with inserts .................. 48bending test ........................................ 48blow time ............................................. 33blow-up ................................................ 24

Ccables, defective .................................. 28capacitor .......................................21, 80capacitors .....................................26, 27capacity switch ................................... 41care ..................................................... 56care and maintenance ......................... 10charging .............................................. 22charging monitoring (ready) ................. 45charging voltage ............................28, 32company specific

maintenance instruction ................. 9company specific work order ................. 9components of the power unit .............. 21compressed air connection .................. 20compressed air supply ........................ 20confirmation ......................................... 85confirmation, operator sign .................... 9connecting the welding gun ................. 18contact ................................... 22, 31, 46contact welding ................................... 26control cable connector ....................... 18control sleeve ...................................... 44controls ............................................... 35cooling fan ........................................... 59

corrective actions ................................ 48cover ................................................... 57cross-slotted screwdriver ..................... 56

Ddelivery ..........................................10, 15display ..........................................22, 31disposal ............................................... 55disposal, environmentally admissible ... 79distance device .................................... 42DVS regulations .................................. 42

Eear protection ................................. 9, 24electrical shock, risk of ....................... 20electrical voltage ............................ 11, 14electromagnetic fields ...........................11energy controller .................................. 28enter key ............................................. 22entire plug connection, destroying ....... 18error codes .......................................... 52external welding start .......................... 45

Ffault recognition ................................... 48feedback ............................................. 86feeding unit, connect the ..................... 44fire extinguisher .............................16, 24fire risk ................................................ 24flange .................................................. 53flash ....................................... 17, 25, 42flat connector ...................................... 54fluids, ingress of .................................. 55foreign bodies, ingress of ..................... 55fume extraction .................................... 24function ............................................... 21functional principle ............................... 10further instructions ............................... 83fuse rating ........................................... 17

Ggap stud welding ................................. 27gas pre-flow time ................................. 41general .................................................. 9general safety instructions ................... 12glossary .............................................. 80gloves .................................................... 9ground cable ..................................19, 57ground clamps ..................................... 19

Index


ground connection ............................... 19guarantee claims .................... 12, 25, 84guarantee clauses ............................... 84guide ................................................... 10

Hheadgear, protective ............................. 24heat built-up ........................................ 16hollow parts, welding on ...................... 24hyper terminal ...............................46, 74

Iintended use ........................................ 12internal thread sleeve ........................... 53ISO-clip ............................................... 54ISO-clip, plastic coated ....................... 54ISO-nail ............................................... 54IT, pin with internal thread ....... 29, 53, 83

Kkeyboard ............................................. 22

Llanguage ............................................. 39LCD display ......................................... 31liability, any ............................ 12, 25, 84library mode ........................................ 34lift (see manual welding gun,

welding head) ............................... 27lift test (welding gun) ............................ 39liquid spatters ...................................... 42liquids, combustible ............................. 16lot ........................................................ 53

Mmagnetic fields ..............................16, 25mains fuse ........................................... 30mains switch ....................................... 30maintenance ................................... 9, 56maintenance instruction ........................ 9maintenance instruction

for your company ........................... 9malfunction ............................................ 9malfunctions and corrective actions ..... 51markings ............................................. 14material combinations ...................29, 83material of the welding element ........... 28material of the workpiece ..................... 28material separation,

environmentally correct .................. 55materials, rapidly oxidizing .................. 26metal spatters ..................................... 24modes ................................................. 33

Nnon-combustible clothes ...................... 24

Ooperating manual ............................ 9, 15operating manual, storage of ................. 9operation, improper .............................. 42operators ............................................... 9order number ....................................... 60

Ppace maker ............................ 11, 17, 25packaging ............................................ 13PAF (process sequence control) .......... 35PAF value ............................................ 35personal injury ......................................11personnel, properly instructed, qualified ... 9personnel, qualified ................................ 9pin UT ................................................. 53pin with internal thread IT ..................... 53pipes, welding to ................................. 28place of operation ................................ 12plunging speed ..............................26, 27power supply ....................................... 17power unit ............................................ 80power unit, switching on ...................... 30prestress at installation .................29, 83process sequence control (PAF) .......... 35production ............................................. 9program mode ..................................... 33protective apron ................................... 24protective equipment ......................17, 25protective equipment, personal .............. 9protective gloves .................................. 24protective goggles .................................. 9PT, threaded stud ................... 29, 53, 83punched plates, welding to .................. 28

Rrange ................................................... 37rectifier ................................................ 80recycling ............................................. 79ref. input .............................................. 36ref. welding .......................................... 36

Index


reference welds ................................... 35regulations ........................................... 81repair ................................................... 79requirements of workplace ................... 16reset .................................................... 40risk of material damage ........................11room adequately ventilated .................. 24rooms exposed to risk of explosion ..... 16RS232 interface ................................... 46

Ssafety goggles with a

window providing protection .......... 24safety instructions .................... 9, 23, 56safety symbols .....................................11serial number ...................................... 84service ................................................. 40service & support ................................. 87service technician .................................. 9set-up .................................................... 9shoes .................................................... 9solenoid ............................................... 22spare part list ...................................... 60spare parts .......................................... 60spare parts, ordering of ..................60, 84spatters ............................................... 42special welding elements ..................... 54spring force (see manual welding gun,

welding head ................................ 28stand-by display .................................. 22standards ............................................ 81standards, actual ...........................12, 42starting-up .....................................10, 16storage ................................................ 13stud feed time (automatic mode) ......... 33stud feeder ....................................20, 80stud welding, functional principle ......... 26stud welding procedure ........................ 23stud welding process ........................... 10stud welding unit ................................. 80support ................................................ 87surface of welding element .................. 48surface, workpiece .............................. 48switch, electronic ................................ 21switching off, completely ..................... 55switching off, temporary ....................... 55switching off the power unit ............10, 55

Ttechnical data ................................10, 59test welding ......................................... 28threaded stud PT ................................. 53threat to life ......................................... 10thyristor .................................. 32, 41, 80tip ignition ............................... 26, 27, 53tolerance range ..............................32, 35tools .................................................... 56torque ............................................29, 83training according to current standards .... 9transportation ................................. 9, 13transportation, packaging, storage ....... 13trigger .................................................. 22type plate ......................................14, 17

Uunauthorized use ................................... 9user qualification, required ..................... 9UT, pin .................................... 29, 53, 83

Vvapors, toxic ........................................ 16vice grip ............................................... 21visual inspection .................................. 47

Wweld, checking the quality of the .......... 47welding, automatic mode ..................... 43welding element .................................. 80welding elements .................... 12, 29, 53welding elements, lot of ....................... 29welding energy ..............................26, 27welding gun ...................................12, 80welding gun cables .............................. 18welding gun support ............................. 42welding head ....................................... 43welding parameters .......................42, 80welding parameters, determination of ... 28welding preparation .............................. 28welding procedure ................................ 42welding process .................................. 10welding spatters .................................. 42welding thyristor .................................. 21welds, high-strength ............................ 28work piece ........................................... 80working place, change of ..................... 20

Index

HBS Bolzenschweiss-Systeme GmbH & Co. KG • Felix-Wankel-Strasse 18 • 85221 Dachau / GermanyPhone +49 (0) 8131 511-0 • Fax +49 (0) 8131 511-100 • E-mail [email protected]

www.hbs-info.com

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