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©HBS Bolzenschweiss-Systeme GmbH & Co. KG

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

10 Preparing Place of Work and Welding Process

10.2  Checking the Welding Gun

 

‹

Always check the operating manual of your welding gun to see whether it may be 

used with this power unit.

The HBS welding guns A 12, A 16, A 22 und AI 06 may only be connected to this 

power unit.

 

‹

Check the chuck of your welding gun for proper fit and ensure it is tightened.

 

‹

Check the bellows of your welding gun for damage.

 

‹

Check if spring force and lift are set according to the welding parameter table in the 

operating manual of the welding gun.

 

Refer here to the operating manual of your welding gun.

Summary of Contents for 93-10-1552A

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 ARC 1550 Power Unit 93 10 1552A 2012...

Page 2: ...bs info com Web www hbs info com ARC 1550 Operating Manual Issue 2012 07 Order No E BA 93 10 1552A Translation of the Original Operating Manual Transmission and duplication of this document disseminat...

Page 3: ...ur 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 e...

Page 4: ...y 16 8 Components of the Power Unit 17 8 1 Main Assemblies 17 8 2 Keyboard and Display 19 8 3 LED Display 20 9 Welding Process 21 10 Preparing Place of Work and Welding Process 27 10 1 Preparing Surfa...

Page 5: ...re Flow Time 42 12 6 Performing the Welding Process 43 13 Checking the Quality of the Weld 47 13 1 Carrying out Visual Inspection 47 13 2 Carrying out Bending Test 48 13 3 Optimization of welding para...

Page 6: ...the stud welding unit You endanger yourself and others if you operate the stud welding unit incor rectly or fail to observe the safety precautions and warnings This can lead to serious injury or exten...

Page 7: ...elds may impair the function of the heart pacemakers 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...

Page 8: ...e clothing Full ear hearing protectors in accordance with the relevant standard A protective apron over your clothing A helmet when welding above your head Safety shoes Remove all inflammable material...

Page 9: ...persons or to considerable material damage Caution Problems in the operating procedure can occur if this information is not observed Forbidden for persons with heart pacemaker Danger Warns you of elec...

Page 10: ...acturer 10 2 Symbols and Terms Used Tip Cross reference to useful information on the use of the stud welding unit Cross references in this operating manual are marked with this symbol or are printed i...

Page 11: ...he electrical energy for stud welding Rectifier Electrical component that converts alternating volta ge into direct voltage Stud feeder Device for automatic feeding of welding elements Stud welding un...

Page 12: ...1552A 1 Operating manual ARC 1550 E BA 93 10 1552A During transport and set up of the machine safety against tilting is only guaranteed up to an angle of 45 A lift unit with a hook can be used for li...

Page 13: ...reserved Reprinting in whole or in part only with the approval of the manufacturer 4 Accessories 4 Accessories The following ground cables are available as accessories No of pieces Part Type Order No...

Page 14: ...ent 1 550 A Current adjustment range 500 1 550 A 500 A 800 A 1 000 A 1 200 A 1 550 A Welding time 5 1 500 msec stepless Primary power 400 V 3 phases 50 60 Hz 63 AT alternative input voltages available...

Page 15: ...6 may only be connected to this power unit The intended use also implies observance of the operating manual on the welding gun used and compliance with the intervals and conditions for inspection and...

Page 16: ...used by e g Normal wear Improper handling Failure to observe the operating manual Failure to observe the safety precautions Use for other than the intended purpose or Transport damage The warranty cla...

Page 17: ...ais 2 Transformer 3 Rectifier 4 Control unit 5 Step switch Mains alternating current is transformed in the transformer 2 and converted in the rectifier 3 The control unit 4 synchronizes the mechanical...

Page 18: ...ting in whole or in part only with the approval of the manufacturer 18 8 Components of the Power Unit Type plate The type plate contains the following information Manufacturer Type Order No Serial No...

Page 19: ...7 8 9 10 Display Longer Energy control Shielding gas Automation not available Shorter Contact Trigger Solenoid Stand by display 10A Locked 10B Ready for welding The condition of the welding unit is m...

Page 20: ...y Green The power unit is ready for welding Red The power unit is locked after welding until there is electrical contact with the work piece if the power unit is overheated the display shows 8 2 After...

Page 21: ...gth of welding time standard ARC or short cycle drawn arc stud wel ding SC The energy source welding rectifier supplied by mains inverter capacitor battery Drawn Arc Stud Welding The HBS stud welding...

Page 22: ...stud is mechanically moved to the work piece On plunging into the weld pool the two weld zones join and solidify The contact of stud and workpiece extinguishes the arc in a short circuit and the main...

Page 23: ...hielding gas SG Shielding gas SG No protection NP No protection NP Material welding element S 235 CrNi steel Aluminum up to 12 mm 0 47 S 235 CrNi steel Aluminum up to 12 mm 0 47 S 235 CrNi steel Brass...

Page 24: ...mic ferrule CF prevents atmosphere from getting to the weld pool by a formation of metal vapor in the arc chamber stabilizes and concentrates the arc thus decreasing the arc blow effect forms the melt...

Page 25: ...Ar 18 CO2 90 Ar 10 CO2 92 Ar 8 CO2 Aluminium and Alumini um alloys DIN EN ISO 14175 I1 DIN EN ISO 14175 I3 85 Ar 15 He 70 Ar 30 He As a result of the higher amount of CO2 the surface tension of the we...

Page 26: ...e energy input and the weld pool are so small that also welding elements up to 12 mm diameter can be welded on thin workpieces Normally welding elements with flange according to current standards are...

Page 27: ...he accident 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...

Page 28: ...the power unit Always place the power unit on a stable level and clean surface Check the condition of all cables and cable connections Have defective cables or their connections immediately repaired...

Page 29: ...welding gun to see whether it may be used with this power unit The HBS welding guns A 12 A 16 A 22 und AI 06 may only be connected to this power unit Check the chuck of your welding gun for proper fit...

Page 30: ...here point 10 Preparing place of work and welding process Electric shock hazard Leave the power unit switched off during connection of the connecting leads In this way you can avoid any unintentional...

Page 31: ...nto the corres ponding socket of the power unit Press in the plug and turn it firmly clockwise to the right Connect the control cable Plug the control cable in the connector of the power unit Twist th...

Page 32: ...loosely made connections will result in damage to the plug connectors Therefore always check that the plug connector is firmly inserted This prevents a poor contact and hence overheating of the plug...

Page 33: ...r unit Connect the gas hose of the welding gun to the gas outlet Set the flow meter of the shielding gas bottle to 8 16 liters min Minimum flow rate for stud welding with shielded gas is 8 l min For s...

Page 34: ...d Have an electrician check whether the plug socket to which you inten ded to connect the power unit is correctly earthed Connect the power unit only to a mains supply with the same mains voltage as t...

Page 35: ...ing unit if you have a heart pacemaker In this case never remain in the vicinity of the stud welding unit during welding Never operate the stud welding unit if persons with heart pacemakers are in the...

Page 36: ...are indicative values and must be checked by means of a test welding on the original material with the same pro perties as the original workpiece When welding with shielding gas a 10 longer time is no...

Page 37: ...ms 1 metric Stud diameter mm Eff diameter mm Material of workpiece Mild steel shiny S235 Steel galvanized S235 d1 d2 I t RD MR M6 4 7 1 500 70 RD MR M8 6 2 1 500 120 RD MR M10 7 9 2 800 120 RD MR M12...

Page 38: ...ime ARC 1550 ms 1 metric Stud diameter mm eff diameter mm Material of workpiece Mild steel shiny S235 Steel galvanized S235 d1 d2 I t DD PD MD M6 5 35 1 500 90 DD PD MD M8 7 19 1 500 160 DD PD MD M10...

Page 39: ...es Material of workpiece Mild steel shiny S235 Steel galvanized S235 d1 d2 I t RD MR 1 4 0 187 1 500 70 RD MR 5 16 0 275 1 500 120 RD MR 3 8 0 312 2 800 120 RD MR 1 2 0 435 2 800 170 RD MR 5 8 0 500 3...

Page 40: ...1 imperial US Stud diameter mm eff diameter mm Material of workpiece Mild steel shiny S235 Steel galvanized S235 d1 d2 I t DD PD MD 1 4 0 21 1 500 90 DD PD MD 5 16 0 28 1 500 160 DD PD MD 3 8 0 36 2...

Page 41: ...ial welds see Point 12 2 Determining the Welding Time Press simultaneously the two arrow keys at the power unit for about one second The display shows 1 0 Enable the energy control with the arrow key...

Page 42: ...e welding gun is removed from the joined wel ding element Adjust the flow meter at the gas bottle to 8 to 16 liters min Press simultaneously the two arrow keys at the power unit for about one second T...

Page 43: ...ctive 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 and...

Page 44: ...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 45: ...ing element has been inserted into the welding gun Insert a welding element if necessary Place the welding gun perpendicularly onto the workpiece as soon as the power unit is ready for the welding pro...

Page 46: ...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 47: ...thin tolerances Correct parameters none Contraction of weld collar Welding element too long Plunging depth or lift too low Increase plunging depth check lift and centering of the ceramic ring Weld pow...

Page 48: ...ressed by bending in a non defined way 1 Welding element 2 Welded joint Place the bending device on the welding ele ment 1 and bend the welding element 1 with the bending device once by 60 in any dire...

Page 49: ...deformation Correct parameters none Fracture within the weld High porosity Weld energy too low Increase current and or welding time Unclean surface Clean the surface Material not suitable for stud wel...

Page 50: ...Welding Parameters As first step conduct the tests outlined under points 13 1 and 13 2 As second step optimize the welding parameters according to the table under point 12 2 Determine Welding Time Op...

Page 51: ...edge of a workpiece a blowing effect can occur This is an undesirable deflection of the light arc This results in uneven melting of the stud material in increased poring and undercuts in the welding...

Page 52: ...sts No LED display at the front Fuse F5 1 AF defective Check fuse F5 1 AF Replace fuse F5 1 AF Qualified specialists No display No ground connection Check ground connec tion on workpiece Tighten groun...

Page 53: ...efective Check solenoid 18 to 22 Replace solenoid Qualified specialists Fuse F3 4 AF defective Check fuse F3 4 AF Replace fuse F3 4 AF Qualified specialists Lifting impossible Solenoid circuit inter r...

Page 54: ...only with the approval of the manufacturer 54 15 Shutting Down 15 Shutting Down Switch off the power unit Pull out the mains plug Disconnect the control cable and welding cables from the power unit Pr...

Page 55: ...rating personnel Carry out only the work described here on your power unit Repairs may only be carried out by appropriately qualified personnel Inform your dealer or your maintenance department 16 1 C...

Page 56: ...condition 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 power unit are still legi ble before starting wo...

Page 57: ...dust free location when not in use Protect the power unit from moisture and metallic contamination Store the power unit only under the following ambient conditions Storage temperature 5 C to 50 C Rela...

Page 58: ...nt 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 2006 95 EG...

Page 59: ...tions of errors Service Support may be done up to the value of EUR without tender Yes No Could you find any damage burning mark on the cables Yes No on chucks Yes No Are all plug and screw connections...

Page 60: ...ed 27 fire hazard 7 form Service Support 53 59 full ear hearing protectors 8 fumes harmful to health 7 27 fuse 34 G gas pre flow time 42 glossary 11 goggles with visor 8 ground cable 32 ground clamps...

Page 61: ...explosive 27 surface of base material 49 surface of welding element 49 switch on the power unit 35 symbols used 9 T test welding 36 transformer 17 troubleshooting 52 type plate 18 34 V vessels welding...

Page 62: ...HBS Bolzenschweiss Systeme GmbH Co KG All rights reserved full or partial reproduction subject to prior approval of the manufacturer 62...

Page 63: ......

Page 64: ...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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