HBS 92-10-0502 Operating Manual Download Page 18 | Manualshive

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HBS 92-10-0502 Operating Manual Download Page 18

©HBS Bolzenschweiss-Systeme GmbH & Co. KG

All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer

18

8 Components of the Stud Welding Unit

8

Components of the Stud Welding Unit

The CDi 502 is ideal for use on construction sites:

Protection against internal soiling:

– Internal fan

– Casing without ventilation slots to the

outside

8.1

Main Assemblies

1- Charging device

A - Primary supply

2 - Control

B - Welding circuit

3 - Welding capacitors

4 - Welding thyristor

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Summary of Contents for 92-10-0502

Page 1: ...HBS Bolzenschweiss Systeme GmbH Co KG All rights reserved Reprinting in whole or in part only with the approval of the manufacturer Operating Manual CDi 502 Stud Welding Unit 92 10 0502 2021...

Page 2: ...nfo com CDi 502 Operating Manual Issue 2021 01 Order No E BA 92 10 0502 Translation of the Original Operating Manual Please keep the manual in a safe place for future reference Transmission and duplic...

Page 3: ...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 ever...

Page 4: ...d Use 16 7 Warranty 17 8 Components of the Stud Welding Unit 18 8 1 Main Assemblies 18 8 2 Operation Panel and Display 20 8 3 Indicator Lights 21 8 4 Mains Switch 21 9 Welding Process 22 9 1 Contact S...

Page 5: ...ng the Charging Voltage 34 12 4 Performing the Welding Process 35 13 Checking the Quality of the Weld 39 13 1 Carrying out Visual Inspection 39 13 2 Carrying out Bending Test 40 13 3 Optimisation of W...

Page 6: ...ding 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 ma...

Page 7: ...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 ar...

Page 8: ...ce with the relevant standard Non flammable 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...

Page 9: ...orkers Strong electromagnetic fields are produced in the vicinity of the stud welding machine during welding To reduce the danger posed by electromagnetic fields we recommend among other things the fo...

Page 10: ...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 acce...

Page 11: ...facturer 2 Symbols and Terms Used Tip Cross reference to useful information on the use of the stud welding machine Cross references in this operating manual are marked with this symbol or are printed...

Page 12: ...nto direct voltage Stud feeder Device for automatic feeding of welding elements Stud welding gun Device for welding of welding elements Stud welding system Stud welding unit including stud welding gun...

Page 13: ...uration of your stud welding unit contains the following parts No of pieces Part Type Order No 1 Stud welding unit CDi 502 92 10 0502 1 Operating manual CDi 502 E BA 92 10 0502 Inspect the shipment fo...

Page 14: ...6 3 C 06 3 C 06 3 CI 03 Easy handling No setting for lift and spring pressure Aluminium to M4 8 Especially suitable for welding of cupped head pins HVCA Welding elements Welding process CD Kontakt Stu...

Page 15: ...to 4 mm Cupped head pins dia 2 and 2 7 mm Welding material Mild steel stainless steel aluminium Welding rate Studs M6 10 studs min Charging voltage 95 V Cupped head pins dia 2 7 mm 10 pins min Chargin...

Page 16: ...ground cable 25 mm2 order no 92 40 154 and CI 03 order no 92 20 254 with ground cable 16 mm2 order no 92 40 091 The intended use also implies observance of the stud welding gun operating manual and co...

Page 17: ...afety precautions Use for other than the intended purpose or Transport damage Warranty entitlement shall no longer be valid if modifications changes or service and repair work is carried out by unauth...

Page 18: ...onents of the Stud Welding Unit 8 Components of the Stud Welding Unit The CDi 502 is ideal for use on construction sites Protection against internal soiling Internal fan Casing without ventilation slo...

Page 19: ...for the welding process The quantity of energy is defined by the operator via the char ging voltage The welding thyristor 4 releases the charging voltage The charging process and the welding process a...

Page 20: ...ltage 2 Decrease 3 Increase 4 Ready 5 Contact 6 Trigger 7 Temperature The stud welding unit is switched on and off via the mains switch on the rear side The charging voltage is indicated on the LED in...

Page 21: ...in 5 V incre ments from 50 V to 100 V Flashing yellow The welding capacitors are charging Constant yellow The welding capacitors are charged Yellow There is electrical contact between the welding elem...

Page 22: ...acitors of the stud welding unit are discharged Because of the high discharge current the ignition tip evaporates explosion like The air gap between welding element and workpiece is ionized see figure...

Page 23: ...the welding element is pressed through the mat up to the workpiece see figure position 1 With ongoing pressure the pressure spring is tensioned until its stop Then the pressure to the welding gun and...

Page 24: ...ing element touches the workpiece the arc extinguishes see figure position 4 With high plunging speed the gap closes faster after evaporation of the ignition tip and welding time arc burn time is redu...

Page 25: ...ccident preven tion regulations This will help to avoid health damage due to fumes and airborne particu lates Danger from fire and explosion Remove all inflammable materials and liquids from your work...

Page 26: ...welding unit Always place the stud welding unit on a stable level and clean surface Check the condition of all cables and cable connections Have defective cables or their connections immediately repai...

Page 27: ...rating manual of your stud welding gun to see whether it may be used with this stud welding unit This stud welding unit can only be used with the HBS stud welding guns C 06 3 order no 92 20 275 or 92...

Page 28: ...e point 10 Preparing Workplace and Welding Pro cess Electric shock hazard Leave the stud welding unit switched off during connection of the connec ting leads In this way you can avoid any unintentiona...

Page 29: ...e right Connect the control cable Plug the control cable into the corresponding socket of the stud welding unit Twist the retaining nut of the control cable connector clock wise Only loosely made conn...

Page 30: ...workpie ce to which you wish to connect the ground clamp Attach the ground clamp to the workpiece as tightly as possible 11 3 Connecting the Stud Welding Unit to the Mains Supply Electric shock hazar...

Page 31: ...s 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...

Page 32: ...ud welding unit via the and push buttons is dependent on among other things The welding gun used The material of the welding element The diameter of the welding element The material of the workpiece D...

Page 33: ...for welding M5 5 mm 5 mm M3 3 16 10 80 4 8 suitable for welding M6 6 mm 6 mm M4 1 4 1 4 8 32 95 Material of workpiece Alloyed steel suitable for welding A2 50 M3 3 mm 1 8 4 55 A2 50 M4 4 mm 5 32 6 65...

Page 34: ...l suitable for welding Galvanised steel suitable for welding 4 8 suitable for welding 2 70 4 8 suitable for welding 2 7 85 Material of workpiece Alloyed steel suitable for welding A2 50 2 70 A2 50 2 7...

Page 35: ...n ductive parts in their vicinity during the welding process These parts are live Never wear metal jewellery even a wristwatch on your body during the welding process This will help to avoid injuries...

Page 36: ...ns Such work may only be carried out by welding specialists Do not carry out such work if you have not been specially trained for it Risk of fire and burns due to glowing weld spatter Wear your person...

Page 37: ...ry Place the welding gun perpendicularly onto the workpiece as soon as the stud welding unit is ready for the welding process Press the welding gun firmly with both hands against the workpiece until t...

Page 38: ...n not to mix welding elements from different batches Carry out test welds again after a batch change Even the slightest changes to the geometry in particular to the tip of the welding elements require...

Page 39: ...ion Condition Possible cause Corrective actions Good welded joint Low spatters around the weld without outer flaws The weld pool forms a collar around the flange of about 1 1 5 mm Correct parameters n...

Page 40: ...ple and as a check for the selected welding parameters The welded joint is stressed by bending in a non defined way 1 Welding element 2 Welded joint Place the bending device on the welding ele ment 1...

Page 41: ...eld energy too low Increase weld energy Plunging speed too low Increase plunging speed Unsuitable stud base material combination Replace welding element or workpiece If the strength of the joint is in...

Page 42: ...edge of a workpiece a blowing effect can occur This is an undesirable deflection of the electric arc This results in uneven melting of the stud material in increased poring and undercuts in the weldin...

Page 43: ...kpiece Properly secure the ground connection Trained personnel Stud welding gun not connected Check gun connection Connect the stud weld ing gun correctly Trained personnel Contact resistance between...

Page 44: ...the approval of the manufacturer 44 14 Troubleshooting Work marked with may only be carried out by qualified electricians Please contact our Service department if none of the measures described remed...

Page 45: ...h the approval of the manufacturer 15 Shutting Down 15 Shutting Down Switch off the stud welding unit Pull out the mains plug Disconnect the control cable and welding cables from the stud welding unit...

Page 46: ...sonnel Carry out only the work described here on your stud welding unit Repairs may only be carried out by appropriately qualified personnel Inform your dealer or your maintenance department 16 1 Clea...

Page 47: ...ndition of the mains cable Inform your dealer or maintenance department if you discover any dama ge Check whether the readings on the display of the stud welding unit are still legible before starting...

Page 48: ...location when not in use Protect the stud welding unit from moisture and metallic contamination Store the stud welding unit only under the following ambient conditions Storage temperature 5 C to 50 C...

Page 49: ...oment of this declaration The product is conform with following further EU Directives including changes to the Directives to be applied at the moment of this declaration Low voltage guideline 2014 35...

Page 50: ...or Detailed descriptions of errors Service Support may be done up to the value of EUR without quotation Yes No Could you find any damage burn marks on the cables Yes No on chucks Yes No Are all plug a...

Page 51: ...isher 8 36 fire extinguisher approved 25 fire hazard 8 form Service Support 44 50 full ear hearing protection 8 fumes harmful to health 7 25 fuse 30 G gap stud welding 23 glossary 12 goggles with viso...

Page 52: ...n 12 14 stud welding system 12 stud welding unit 12 substances explosive 25 surface of base material 41 surface of welding element 41 switching on the stud welding unit 32 symbols used 10 T troublesho...

Page 53: ......

Page 54: ...HBS Bolzenschweiss Systeme GmbH Co KG Felix Wankel Strasse 18 85221 DACHAU GERMANY Phone 49 8131 511 0 Fax 49 8131 511 100 E mail international hbs info com www hbs info com...

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