HBS IT 2002 Bedienungsanleitung

©HBS Bolzenschweiss-Systeme GmbH & Co. KG

Operating Manual

IT 2002

Stud Welding Unit

Ceramic/Gas Version

93-60-2202

2021

After-sales service for Germany:

HBS Bolzenschweiss-Systeme GmbH & Co. KG

Felix-Wankel-Straße 18

85221 Dachau

GERMANY

Phone +49 8131 511-0

Fax +49 8131 511-100

E-mail [email protected]

Web www.hbs-info.com

IT 2002 Operating Manual Issue 2021-01 Order No. E-BA 93-60-2202

Translation of the Original Operating Manual

Please keep the manual in a safe place for future reference.

Transmission and duplication of this document, dissemination and notication

of the contents are not permitted unless expressly approved.

All rights, errors and technical amendments reserved.

3©HBS Bolzenschweiss-Systeme GmbH & Co. KG

Dear Customer,

Many thanks for buying a stud welding machine from HBS Bolzenschweiss-Syste-

me.

We at HBS wish you success at all times when working with this stud welding ma-

chine.

The high level of quality of our products is guaranteed by ongoing further deve-

lopment in the design, equipment and accessories. This may result in differences

between the present operating manual and your product. No claims can therefore be

derived from the data, illustrations and descriptions.

We have compiled the data and information in this reference work with the greatest

care, and have made every effort to ensure that the information contained in this

manual was correct and up-to-date at the time of delivery. We can nevertheless give

no guarantee for an absolutely error-free document.

Should you discover any errors or unclear points when reading this operating manu-

al, please do not hesitate to contact us.

We would also be grateful for any feedback should you have any suggestions or

complaints to make about our product.

HBS Bolzenschweiss-Systeme GmbH & Co. KG

Felix-Wankel-Strasse 18

85221 Dachau

GERMANY

©HBS Bolzenschweiss-Systeme GmbH & Co. KG

Table of Contents

1 Important Safety Precautions ................................................................... 6

2 Symbols and Terms Used ....................................................................... 10

3 Scope of Supply ....................................................................................... 13

4 Accessories .............................................................................................. 14

5 Technical Data .......................................................................................... 15

6 Intended Use ............................................................................................ 16

7 Warranty ................................................................................................... 17

8 Components of the Stud Welding Unit .................................................. 18

8.1 Main Assemblies ................................................................................................... 18

8.2 Control Panel and Display .................................................................................... 20

9 Welding Process ...................................................................................... 22

Drawn-Arc Stud Welding ...................................................................................... 22

10 Preparing Workplace and Welding Process .......................................... 28

10.1 Preparing Surfaces ............................................................................................... 29

10.2 Checking the Stud Welding Gun .......................................................................... 30

11 Connection ............................................................................................... 31

11.1 Connecting the Welding Gun to the Stud Welding Unit ........................................ 32

11.2 Shielding Gas Connection .................................................................................... 33

11.3 Connecting the Ground Cable .............................................................................. 34

11.4 Connecting the Stud Welding Unit to the Mains Supply ....................................... 35

12 Welding ..................................................................................................... 36

12.1 Switching on the Stud Welding Unit ..................................................................... 37

12.2 Determining the Welding Time and the Welding Current ...................................... 37

5©HBS Bolzenschweiss-Systeme GmbH & Co. KG

Table of Contents

12.3 Checking Shielding Gas Flow Rate ...................................................................... 44

12.4 Possible Settings .................................................................................................. 45

12.4.1 Setting the Welding Parameters ........................................................................................ 45

Adjusting the Welding Time ................................................................................................ 45

Adjusting the Welding Current ........................................................................................... 45

Adjusting the Gas Pre-Flow Time ....................................................................................... 46

12.4.2 Library Mode ...................................................................................................................... 47

12.4.3 Conversion Current Curve ................................................................................................. 47

12.5 Performing the Welding Process .......................................................................... 48

13 Checking the Quality of the Weld ........................................................... 52

13.1 Carrying out Visual Inspection .............................................................................. 52

13.2 Carrying out Bending Test .................................................................................... 53

13.3 Optimisation of Welding Parameters .................................................................... 55

13.4 Blowing Effect and Remedies ............................................................................... 56

14 Troubleshooting ....................................................................................... 57

15 Shutting Down ......................................................................................... 59

16 Maintenance and Care ............................................................................. 60

16.1 Cleaning ............................................................................................................... 60

16.2 Inspection and Tests ............................................................................................. 61

17 Storage ..................................................................................................... 62

18 Disposal .................................................................................................... 62

EC Declaration of Conformity ............................................................................. 63

Service & Support ................................................................................................ 64

Index ...................................................................................................................... 65

©HBS Bolzenschweiss-Systeme GmbH & Co. KG

1 Important Safety Precautions

The target group for this manual are qualied personnel who in view of their techni-

cal training, know-how and experience and knowledge of applicable regulations are

able to assess the work assigned to them and recognise potential hazards.

Danger from incorrect use

Use the stud welding machine only for the purpose described in this ma-

nual.

Otherwise you may endanger yourself or damage the stud welding machine.

You endanger yourself and others if you operate the stud welding machine

incorrectly or fail to observe the safety precautions and warnings. This can

lead to serious injury or extensive material damage.

Danger for unauthorised operating personnel

Work with the stud welding machine only when

– You are appropriately trained, instructed and authorised to do so, and

– You have read and completely understood this operating manual.

Never work with the stud welding machine when you are under the inu-

ence of

– Alcohol,

– Drugs or

– Medication.

Danger from unauthorised modications

Never modify the stud welding machine or parts thereof without obtaining

a clearance certicate from the manufacturer.

You will otherwise endanger yourself. This can lead to serious injury or ex-

tensive material damage.

7©HBS Bolzenschweiss-Systeme GmbH & Co. KG

1 Important Safety Precautions

Life-threatening danger for wearers of active implanted cardiac

devices

Danger for workers at particular risk within the meaning of the

EMF directive

Persons at particular risk within the meaning of the EMF directive are:

– Workers with active implanted medical devices

– Workers with passive implanted medical devices that contain metal

– Workers with medical devices worn on the body

– Pregnant workers.

Never operate the stud welding machine if you are among the group

of workers at particular risk within the meaning of the EMF directive.

In this case, never remain in the vicinity of the stud welding machine

during welding.

Never operate the stud welding machine if persons are located

nearby who are among the group of workers at particular risk within

the meaning of the EMF directive.

Strong electromagnetic elds are produced in the vicinity of the stud

welding machine during welding. These elds can adversely affect the

function of medical devices as well as the course of a pregnancy.

Danger from fumes and airborne particulates

Switch on the welding fume extractor at the place of work.

Ensure that the room is well ventilated.

Never weld in rooms with a ceiling height of less than 3 m.

Observe furthermore your working instructions and the accident

prevention regulations.

This will help to avoid health damage due to fumes and airborne parti-

culates.

©HBS Bolzenschweiss-Systeme GmbH & Co. KG

1 Important Safety Precautions

Danger from glowing metal spatter (re hazard)

Glowing hot weld spatter and liquid splashes, ashes of light and a

loud bang > 90 dB (A) must be anticipated during stud welding.

Inform colleagues working in the immediate vicinity accordingly

before starting work.

Ensure that an approved re extinguisher is available at the work-

place.

Do not weld when wearing working clothes soiled with ammable

substances such as oil, grease, petroleum, etc.

Wear your proper protective clothing, such as:

– Protective gloves in accordance with the relevant standard,

– Non-ammable clothing,

– A protective apron over your clothing,

– Full-ear hearing protection in accordance with the relevant stan-

dard,

– A safety helmet when welding above your head,

– Safety shoes,

– Safety goggles with sight glass of protection level 2 in compli-

ance with the applicable standards and do not look directly into

the electric arc.

Remove all ammable materials and liquids from the vicinity of the

work area before starting welding.

Weld at a safe distance from ammable materials or liquids.

Select a safety distance large enough to ensure that no danger can

arise from weld spatter.

Protection of the stud welding unit

Protect the stud welding machine against the ingress of foreign

matter and liquids caused by cutting or grinding work in the vicinity

of your work area.

This will help to prolong the service life of your stud welding machine.

9©HBS Bolzenschweiss-Systeme GmbH & Co. KG

1 Important Safety Precautions

Safety notices in accordance with EMF directive 2013/35/EU

Currents owing through electrical conductors during stud welding cause electric

and magnetic elds that can occur, in particular, near the hand-held welding guns,

the welding arrangement (e.g., welding cables) and the welding power sources.

Due to the high currents, high EMF exposures may occur.

Danger for workers at particular risk within the meaning of the

EMF directive

Persons at particular risk within the meaning of the EMF directive are:

– Workers with active implanted medical devices

– Workers with passive implanted medical devices that contain metal

– Workers with medical devices worn on the body

– Pregnant workers.

Strong electromagnetic elds are produced in the vicinity of the stud

welding machine during welding.

To reduce the danger posed by electromagnetic elds, we recommend, among other

things, the following rules of conduct:

Lay all cables as close together as possible.

For proper bundling and safeguarding of the cables, HBS offers protective tubes in

various sizes.

Do not position yourself between the welding cables.

Only lay the cables to one side and position them as far as possible from the

operating personnel.

Do not loop the cables over your body, especially not at head level.

Completely unwind the welding cables.

Use the shortest possible welding cables.

Place portable welding power sources as far away as possible while welding.

If possible, do not operate welding power sources in the immediate vicinity of

other persons, do not sit directly next to the welding power source while working

and do not lean against it.

In addition to these safety notices, also observe your work instructions and acci-

dent prevention regulations.

2 Symbols and Terms Used

The symbols used in this operating manual have the following meanings:

Danger

Warns you of hazards that can lead to injury of persons or to

considerable material damage.

Caution

Problems in operating may occur if this information is not observed.

No access for people with active implanted cardiac devices

No access for persons with implants made of metal

No access for pregnant women

Danger

Warns you of electrical hazards

Danger

Warns you of electromagnetic elds that can be generated during welding

These symbols prompt you to wear personal protective clothing when

working with the stud welding unit.

This symbol prompts you to wear ear protection. A loud bang > 90 dB (A)

can occur during the welding process.

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