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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

CI 03 Operating Manual Issue 2016-05  Order No. E-BA 92-20-254

Translation of the Original Operating Manual

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

Transmission and duplication of this document, dissemination and notification 

of the contents are not permitted unless expressly approved.
All rights, errors and technical amendments reserved.

© HBS Bolzenschweiss-Systeme GmbH & Co. KG

Summary of Contents for 92-20-254

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 CI 03 Stud Welding Gun 92 20 254 2016 ...

Page 2: ...o com CI 03 Operating Manual Issue 2016 05 Order No E BA 92 20 254 Translation of the Original Operating Manual Please keep the manual in a safe place for future reference Transmission and duplication of this document dissemination and notification of the contents are not permitted unless expressly approved All rights errors and technical amendments reserved HBS Bolzenschweiss Systeme GmbH Co KG ...

Page 3: ...d 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 ...

Page 4: ... 6 2 Symbols and Terms Used 9 3 Scope of Supply 12 4 Accessories 12 5 Technical Data 13 6 Intended Use 14 7 Warranty 15 8 Design and Function 16 9 Welding Process 17 10 Preparing the Stud Welding Gun 18 10 1 Mounting the Chuck 18 10 2 Setting the Welding Parameters 19 Adjusting Spring Force 20 11 Welding 21 12 Troubleshooting 22 13 Maintenance and Care 24 13 1 Cleaning 24 13 2 Inspection and Tests...

Page 5: ...Co KG All rights reserved Reprinting in whole or in part only with the approval of the manufacturer Table of Contents 14 Storage 26 15 Disposal 26 Declaration of Incorporation of partly completed Machinery 27 Service Support 28 Index 29 ...

Page 6: ...lding 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 completel...

Page 7: ...welding machine during welding These fields could impact the func tion of heart pacemakers or implanted defibrillators 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 regula...

Page 8: ...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 light arc Remove all flammable materials and liquids from the vicinity of the work area before starting welding Weld at a safe distance from flammable materials or liquids Select a safety distance large enough t...

Page 9: ...ons or to considerable material damage Caution Problems with the operating procedures can occur if this information is not observed No access for people with active implanted cardiac devices Danger Warns you of electrical hazards Danger Warns you of electromagnetic fields that can be generated during welding These symbols prompt you to wear personal protective clothing when working with the stud w...

Page 10: ...cturer 10 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 in italics Fire hazard Have a suitable fire extinguisher for the working area ready before starting work Work instruction List ...

Page 11: ...ng vol tage into direct voltage Stud feeder Device for automatic feeding of welding elements Stud welding gun Device for welding of welding elements Stud welding machine Stud welding unit including stud welding gun Stud welding unit Device for provision of the electrical energy for stud welding Thyristor Electronic component for contact free switching of high currents switching takes place via the...

Page 12: ...manual CI 03 E BA 92 20 254 1 Double open ended wrench AF 14 17 80 10 069 Inspect the shipment for visible damage and completeness immediately on re ceipt Report any transport damage or missing components immediately to the delive ring shipping agent or the dealer address see page 2 4 Accessories For example Accessories ISO TS Chuck ISO TS and double open ended wrench dia 30 mm 92 40 066A Accessor...

Page 13: ...o current standards Welding range Cupped head pins dia 2 2 7 mm Pin length 9 5 to 152 4 mm Pin material Mild steel stainless steel Pin type Cupped head pins Spring force Adjustable arresting Welding cable 10 m IP Code IP 20 protect against humidity Workplace noise level 90 dB A may occur during welding Ambient temperature limits 0 C to 40 C Dimension L x B x H 175 x 50 x 145 mm without cable and t...

Page 14: ... with standardised stud welding elements The use of any other elements will result in the desired strength of the welded joint being diminished The stud welding gun must only be connected to HBS stud welding units Always check with the operating manual of your stud welding unit whether this stud welding gun may be used Observation of the operating manual of the stud welding unit being used is also...

Page 15: ...safety 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 unauthorised persons or without the knowledge of the manufacturer Invalidation of warranty entitlement shall also render the declara tion of conformity invalid The CE marking shall be declared invalid by t...

Page 16: ... Positioned at the front of the stud welding gun are the welding piston and the retai ning nut used to fix the manual chuck At the front of the stud welding gun the gun head 5 and the spacer 6 are ins talled At the rear there is the mechanism for spring force adjustment 1 At the front of the stud welding gun handle the welding gun trigger 4 is installed It is used to trigger the welding process Th...

Page 17: ...nly with the approval of the manufacturer 9 Welding Process 9 Welding Process This stud welding gun may only be used for capacitor discharge stud welding with tip ignition contact welding Please refer to the original operating manual of the connected stud welding unit for the welding procedure ...

Page 18: ...gun to the stud welding unit until it has been prepared In this way you can avoid any unintentional starting of the welding process 10 1 Mounting the Chuck Select a chuck suitable for your welding element Cupped head pin Cupped head pin dimension Chuck with solenoid Ø in mm 30 82 50 310B 28 82 50 308A Loosen the retaining nut Put the chuck with loose retaining nut up to the stop into the piston of...

Page 19: ...nsulation Material of welding elements Diameter of welding elements Welding gun parameters 1 metric imperial CI 03 D mm D Spring force Scaling Material of workpiece Mild steel suitable for welding Galvanised steel suitble for welding 4 8 suitable for welding 2 14 ga 6 4 8 suitable for welding 2 7 12 ga 6 Material of workpiece Alloyed steel suitable for welding A2 50 2 14 ga 6 A2 50 2 7 12 ga 6 1 t...

Page 20: ...ce Turn the adjustment piece for spring force 2 up to the stop in min direction Now turn the end ring of the welding gun until the 0 position is aligned with the 0 position of the marking on the adjustment piece for spring force Now turn the adjustment piece for spring force to the selected value see table under point 10 2 You thus determine the insertion rate The scale on the adjustment piece for...

Page 21: ...al of the HBS stud welding unit Danger if used other than for the intended purpose Use the stud welding gun only for CD stud welding contact welding and only in combination with stud welding units from manufacturer HBS Bolzenschweiss Systeme GmbH Co KG Felix Wankel Strasse 18 85221 Dachau GERMANY Always check with the operating manual of your stud welding unit whether this stud welding gun may be ...

Page 22: ...eplace o rings Trained personnel Stud welding gun does not weld Control cable defective with present contact signal on stud welding unit Check control cable for electrical flow at control cable sleeve Pin 3 and 4 with pressed welding gun trigger In case of no flow Replace control cable Qualified specialists Micro switch defective with present contact signal on stud welding unit Check micro switch ...

Page 23: ...pproval of the manufacturer 12 Troubleshooting Work marked with may only be carried out by qualified electricians Please contact our Service department if none of the measures described remedies the situation Please use the form Service Repair in the annex to send in the stud welding unit or stud welding gun ...

Page 24: ...e stud welding unit Prior to this disconnect the stud welding gun from the stud welding unit Danger from insufficiently qualified operating personnel Carry out only the work described here on your stud welding gun Repairs may only be carried out by appropriately qualified personnel Inform your dealer or your maintenance department 13 1 Cleaning Clean the casing of your stud welding gun with a slig...

Page 25: ...nting the chuck in this manual Before every use inspect the bellows on the front part of the stud welding gun for proper seating and or damage Never work with damaged or incorrectly seated bellows This will contribute to a long service life of your stud welding gun Inform your dealer or maintenance department if you discover any dama ge Before every use check that the type designations and adjustm...

Page 26: ...hen not in use Protect the stud welding gun from moisture and metallic contamination Store the stud welding gun only under the following ambient conditions Storage temperature 5 C to 50 C 23 F to 122 F Relative humidity 0 50 at 40 C 104 F 0 90 at 20 C 68 F 15 Disposal Dispose of the stud welding gun only via the manufacturer or a specia list disposal company Never dispose of the stud welding gun i...

Page 27: ... 8 1 5 10 1 5 11 1 5 15 1 5 16 1 6 1 1 6 2 1 6 3 1 6 4 1 7 1 1 1 7 2 1 7 3 1 7 4 that special technical documentation was compiled in accordance with Part B of Annex VII of the above mentioned regulation and will be transmitted in response to a reasoned request by the national authorities as follows The above mentioned documents will be transmitted by e mail as a data file in German language that ...

Page 28: ...butor 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 and screw connections tightly fastened Yes No Are there any burn marks on plug or screw connections Yes No Is there any other visual damage e g cracks dents Yes No Have you checked the fuses Yes No ...

Page 29: ... to health 7 G glossary 11 goggles with visor 8 H hazards for the machine 9 hazards for the operator 9 heart pacemaker 7 9 helmet 8 I intended use 14 21 L light arc 11 M maintenance and care 24 O operating manual 12 P protective apron 8 protective equipment 8 protective equipment personal 9 protective gloves 8 R rectifier 11 S safety goggles 9 safety goggles with sight glass 8 safety precautions 6...

Page 30: ... HBS Bolzenschweiss Systeme GmbH Co KG All rights reserved full or partial reproduction subject to prior approval of the manufacturer 30 ...

Page 31: ......

Page 32: ...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 post hbs info com www hbs info com ...

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