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34

A 12 Order No. BA 93-20-270   Issue 01.03.08

Type of fracture

Possible cause

Corrective actions

Base material buckling

- Correct parameters

- none

Fracture in welding element

above weld collar

- Correct parameters

- none

Fracture in the weld metal

Many pores

- Welding energy too low

- Plunging speed too low

- Unsuitable stud/base

  material combination

- Increase welding energy

- Increase plunging speed

- Replace welding element or 

workpiece

Fracture in the weld metal

Shiny fracture  

surface

- Welding time too short

- Increase welding time

Bending Test

Summary of Contents for 93-20-270

Page 1: ...A 12 Welding Gun 93 20 270 Operating Manual ...

Page 2: ...e 18 85221 Dachau Germany Phone 49 0 8131 511 0 Fax 49 0 8131 511 100 E mail post hbs info com Web 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 copyright owner Adaptations errors and technical modifications reserved without prior notice HBS Bolzenschweiss Systeme GmbH Co KG ...

Page 3: ... malfunction In case of accident inform a physician and the responsible official body THREATTOLIFE Persons fitted with a pace maker must not operate the stud welding machine MAGNETICFIELDS During stud welding strong electro magnetic fields are generated 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 welding...

Page 4: ...ore copies please provide the order number listed in the foot line Importantreminder Dataandinformationhereinwerecollectedwithgreatestcare Althoughwedidourvery besttocorrectlyupdateanyinformationuptothetimeofdelivery thereisnoguarantee in 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 Strasse18 85221 Da...

Page 5: ...6 3 4 Change Working Place 17 4 Function 18 4 1 Components of the Welding Gun Ceramic 18 4 2 Adjustment of Projection Plunging Depth 19 4 3 Adjustment of Lift 19 4 4 Adjustment of Spring Force 19 5 Stud Welding Procedure 21 5 1 Safety Instructions 21 5 2 Functional Principle of Stud Welding 24 5 2 1 Drawn Arc Stud Welding with Ceramic Ferrule 26 5 2 2 Drawn Arc Stud Welding with Shielding Gas 26 5 2 3...

Page 6: ...ching off the Welding Gun 40 6 1 Temporary Switching off 40 6 2 Disposal 40 7 Care and Maintenance 41 7 1 Safety Instructions 41 7 2 Regular Maintenance Operations 42 8 Appendix 43 8 1 Technical Data 43 8 2 Spare Parts 44 8 3 Accessories 50 8 4 Environmentally Admissible Disposal 52 Glossary 53 Regulations and Standards 54 Further Instructions 56 Guarantee Clauses 57 EU Statement of Conformity 58 Con...

Page 7: ...he safety instructions Before starting up the welding gun 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 operating processes Contact us if there are any doubts on certain operating procedures Protect the welding gun against unauthorized use Inform our service in case of malfuncti...

Page 8: ...the Welding Gun in Chapter 6 CareandMaintenance in Chapter 7 Technical Data and much more in Appendix THREAT TO LIFE and risk of serious health and material damage in case of improper use of the welding gun Observe all notes in this operating manual Note for qualified operators see chapter 1 All instructions contained in this manual must also be observed by qualified operators The welding process and ...

Page 9: ...l 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 ...

Page 10: ...ents according to actual standards see chapter 5 and appendix Any other use is regarded as not used as directed The manufacturer is not liable for damages resulting from the welding gun not used as directed Any risk is carried by the user The welding gun is designed according to specific standards and accident prevention regulations Basics are European Union guidelines and in Germany valid standards P...

Page 11: ...n only be checked before starting up by visual inspection visibledamage The following items are to be observed if the welding gun is not to be put into operation immediatelyafterdelivery The welding gun must be stored in a secure place The welding gun must be protected against humidity dust metallic dirt Storagetemperature 5 C to 50 C Relativehumidity 0 to 50 at 40 C 0 to 90 at 20 C If you resell the we...

Page 12: ...visible Type plate The type plate contains the following data Manufacturer Type OrderNo SerialNo Primaryvoltage Fuse Powerconsumption 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 ...

Page 13: ...20 270 Issue 01 03 08 13 2 Delivery The basic equipment of your welding gun contains the following components No of pieces Part Type OrderNo 1 Welding gun cable length 5 m A 12 93 20 270 1 OperatingManual A 12 BA93 20 270 ...

Page 14: ...egulations 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 of the 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 is sensitive to w...

Page 15: ...patters 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 actual standards see appendix 3 2 Connecting the Welding Gun to the Power Unit Switch off the power unit In this way you avoid any risk of electrical shock Plug the welding cable of the welding gun into the related so...

Page 16: ...e cables Strong magnetic fields occur during welding which may cause a movement of the cables This may cause a slackness of the connections 3 3 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 are properly locked In c...

Page 17: ... between the two ground clamps 3 4 Change Working Place Switch off the power unit In this way you avoid any risk of electrical shock When you move your workplace disconnect the welding gun and the ground cables from the power unit Proceed in reversed sequence as described in sections 3 2 and 3 3 After changing the workplace check the welding gun and the ground cables for possible damage or missing ...

Page 18: ...e welding gun handle to the welding gun Positioned at the front of the welding gun are the welding piston and the retaining nut 6 used to fix the manual chuck At the front of the welding gun the face plate 5 is installed Here the tripods as described in section 8 2 are mounted At the rear there is the mechanism for lift off adjustment 8 rotating graduated ring 7 and for spring force adjustment 1 Atthefr...

Page 19: ...uired lift value in steps of 0 2 mm distance between 0 and 0 2 mm is required to set up the internal adjustment wheel of the length compensation device Now push the adjustment wheel back into its locking position 4 4 Adjustment of Spring Force Rotate the adjustment wheel to the selected reference value to set the effective pre tensioning of the spring Depending on your welding job you may change the spri...

Page 20: ...values of the welding parameters to be adjusted like welding currentandweldingtime fromtheoperatingmanualoftheweldingpowerunittowhich the stud welding gun A 12 is connected Switch on the power unit Set up the welding time required for your welding task and where appropriate welding current see table operating manual of the unit Place the gun vertically onto the workpiece The welding is released by t...

Page 21: ...ctrical shock and arc During the actual stud welding process do not touch the stud chuck or retaining nut nor any electrically conductive parts in 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 conductiveparts with restri...

Page 22: ...ds see appendix non combustibleclothes 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 in vicinity 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 welding sp...

Page 23: ...ters 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 actual standards see appendix MAGNETIC FIELDS During stud welding strong magnetic fields are present Do not weld in the vicinity of electrical systems and machines which could be affected Warning Unauthorized interference with the stud welding unit a...

Page 24: ...ee appendix The standards assign this method of joining pin shaped elements with plane workpieces to the so called Arc Pressure Welding code BH Joining is carried out in plastic or liquefied condition of the welding zone The process canbecarriedoutmechanicallyorautomatically dependingontheusedweldingguns weldingheads Generally thepositivepoleofthepowerunitisconnectedtotheworkpiece Thewelding elementi...

Page 25: ...lding Item Drawn arc stud welding with ceramic ferrule ring Drawn arc stud welding with shielding gas Short cycle stud welding with shielding gas Capacitor discharge stud welding with drawn arc Diameter welding element d metric mm imperial 3 25 4 or 12 gage to 1 3 12 16 4 or 12 gage to 1 2 5 8 3 12 4 or 12 gage to 1 2 2 8 14 gage to 5 16 Max current I A 3000 2500 1500 5000 Welding time t ms 50 200...

Page 26: ...the weld pool Standardweldingelementsandceramicferrulesaredescribedinseveralstandards see appendix When using concrete anchors or shear connectors the front area can be plane constructed with a small pressed in aluminum ball Studs with cone shaped front area and aluminum ball are preferably used with ceramicferrule 5 2 2 Drawn Arc Stud Welding with Shielding Gas Drawn arcstudweldingwithshieldinggasis...

Page 27: ...er shielding gas With shielding gas you should only weld in position PA verti cal because due to gravity the shielding gas cannot prevent flow of the molten metal 5 2 3 Short Cycle Drawn Arc Stud Welding with Shielding Gas Short cycledrawn arcweldingwithshieldinggasisusedforweldingelementswithina diameter range of 3 to 12 mm nominal diameter without flange and welding times between 5 and 100 ms Duet...

Page 28: ...ements chapter3 Starting up Check all cables and connections for proper condition Replace immediately defective cables and cable connections to avoid electrical shocks Check the chuck for proper seat see operating manual of according welding gun Before welding make sure that the bellows are checked for damage and proper seat 5 4 High strength Welds The following must be removed both from the weld zo...

Page 29: ... Welding time ms Welding current A Welding time ms metric imperial metric imperial metric mm imperial M3 1 8 not standardized 3 4 or 12 gage 3 4 or 12 gage 240 60 M4 5 32 not standardized 4 8 4 8 320 80 M5 3 16 not standardized 5 10 or 3 16 5 10 or 3 16 400 100 M6 1 4 4 7 0 19 380 100 6 1 4 6 1 4 480 120 M8 5 16 6 2 0 24 500 130 8 5 16 8 5 16 640 160 M10 3 8 7 9 0 31 640 160 10 7 16 10 7 16 800 20...

Page 30: ... normally selected When welding alloyed steel a 10 lower current is normally selected The given values apply to weldings in the welding position PA The welding time shall be reduced for welding in the welding position PC In the case of short cycle stud welding the welding time is less than 100 ms It depends not only on the stud diameter but also on the available current intensity I A min 100 x Ø mm T...

Page 31: ...Wear always your personal protective equipment according to actual standards 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 welding gun support distance device is evenly seated on the workpiece hold the weldin...

Page 32: ...flaws The weld pool forms a collar around the flange of about 1 1 5 mm Correct parameters None Cold weld pool Gap 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 pool Many spatters around the weld Heat input too high Plunging speed too low Reduce c...

Page 33: ...ections 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 in chapter 5 You don t need to test all studs It is sufficient to carry out stud tests 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 m...

Page 34: ...ement above weld collar Correct parameters none Fracture in the weld metal Many pores Welding energy too low Plunging speed too low Unsuitable stud base material combination Increase welding energy Increase plunging speed Replace welding element or workpiece Fracture in the weld metal Shiny fracture surface Welding time too short Increase welding time Bending Test ...

Page 35: ...tion of the arc It causes a single sided melting of the stud material increased pore formation and undercuts in the weldingarea The arc blow effect is proportional to the current and can be influenced by symmetric installation of the ground clamps by fitting of compensation masses or by rotating the welding gun around its vertical axis applies for welding guns with external welding cable Arc blow effect...

Page 36: ... control cable Qualified personnel Welding gun trigger defective no trigger signal available at pow er unit Check control cable for electrical flow at control cable sleeve Pin 3 4 w ith pressed w elding gun trigger In case of no signal Replace micro sw itch Qualified personnel Ground connection defective no contact signal on pow er unit Check w hether ground cable is connected to w orkpiece Connec...

Page 37: ...ic Shielding gas M6 15 40 mm 83 50 006 83 51 006 M8 15 50 mm 83 50 008 83 51 008 M10 20 55 mm 83 50 010 83 51 010 M12 25 60 mm 83 50 012 83 51 012 M16 30 65 mm 83 50 016 83 51 016 Chuck Materials S235 St37 3k 4 8 1 4301 1 4303 Threaded stud DD MD Diameter Length Ceramic Shielding gas M6 15 30 mm 83 50 006 83 51 006 M8 15 50 mm 83 50 008 83 51 008 M10 20 55 mm 83 50 010 83 51 010 M12 25 60 mm 83 50...

Page 38: ...1 010 M12 20 50 mm 83 50 012 83 51 012 M16 20 50 mm 83 50 016 Chuck Materials S235 St37 3k 4 8 1 4301 1 4303 Head stud SD Diameter Length Chuck ceramic 1 4 6 50 100 mm 83 53 006 3 8 10 50 175 mm 83 53 010 1 2 13 50 175 mm 83 53 012 5 8 16 50 175 mm 83 53 019 3 4 19 50 175 mm 83 53 019 7 8 22 75 200 mm 83 53 022 Materials S235 St37 3k 4 8 1 4301 1 4303 Ceramic ferrule RF for threaded stud RD Diamet...

Page 39: ... 222 Materials S235 St37 3k 4 8 1 4301 1 4303 Threaded stud FD with flange Diameter Length Chuck M3 on request 82 50 003 M4 on request 82 50 004 M5 on request 82 50 005 M6 on request 82 50 006 M8 on request 82 50 008 Materials S235 St37 3k 4 8 1 4301 X mas tree stud Diameter Length Chuck 5 on request 82 50 005 6 on request 82 50 006 Materials S235 St37 3k 4 8 1 4301 1 4303 Welookforwardtoconsultyo...

Page 40: ...6 1 Temporary Switching off Switch off the power unit Unplug the control cable and the welding cable from the power unit Protect the stud welding gun against ingress of fluids and foreign bodies 6 2 Disposal If you shut down the installation you can return the complete welding gun to HBS for address see page ii We will take care for environmentally correct material separation and disposal ...

Page 41: ...e long life expectancy 7 1 Safety Instructions Let maintenance and repair operations be carried out only by qualified personnel or by your competent service technician Before you start any cleaning and maintenance operation with the welding gun always switch the power unit off and discon nect control cable and welding cable from power unit ...

Page 42: ...on nect control cable and welding cable from power unit Clean the surface of the welding gun of dirt and dust Do not use any solvent containing cleaning agents Solvent containing cleaning agents may damage the plastic components of the welding gun Check the chuck from time to time If you disclose scorching areas on the chuck replace the chuck see chapter 4 and 5 Before you start working check the bel...

Page 43: ... 0 39 to 15 74 dependingontripod Stud material Mild steel or stainless steel Stud type Any type or shape special chucks if required Lengthadjustment 3 mm automatic Stroke Adjustment range 3 mm 0 12 lockable Springpressure Adjustable arresting Welding cable 5 m 16 40 Insulation class IP 20 protect against humidity Workplacenoiselevel Up to 90 dB A may occur during welding Operationalandstorageconditions Acc...

Page 44: ...766 Pressurespring armature 27 1 80 09 008B Solenoid complete 29 1 80 09 800 Springwasher 31 1 88 11 417 Pressurespring 33 1 88 11 418 Shockabsorber 35 1 80 09 022 Axial arrest 37 1 88 10 674A Adjustment part lift complete 39 1 80 11 272 Sticker spring force 41 1 88 11 329 Endring 49 1 80 70 142 Connectinglinecomplete 51 1 80 10 019 Antikink bushing 53 8 80 10 021 Cable clamp 55 1 80 50 059 Cablecon...

Page 45: ...A 12 Order No BA 93 20 270 Issue 01 03 08 45 Welding gun type A 12 93 20 270 ...

Page 46: ...ption 1 1 80 40 149 Gas foot piece 2 1 80 40 538 Foot piece 3 1 80 10 113 Bellowsholder G 4 1 80 10 176 Bellows 5 2 80 40 411 Leg8 220 6 2 80 40 531 Coverplatetripod 7 5 5 m 80 11 420 Plastic hose 8 1 80 10 024 Nipple 9 1 80 10 139 Connectormale 10 1 80 11 421 Swivelconnection 14 2 80 90 116 Screw M6 x 16 15 2 80 90 290 Screw M5 x 30 ...

Page 47: ...A 12 Order No BA 93 20 270 Issue 01 03 08 47 Shielding gas tripod complete A 12 93 40 021 ...

Page 48: ...e 01 03 08 Spare part list ceramic tripod complete A 12 93 40 022 Pos Quantity OrderNo Description 1 2 80 40 531 Coverplatetripod 2 1 80 40 410 Foot piece alu 4 2 80 40 411 Leg8 220 5 2 80 90 124 Screw M5 x 6 6 2 80 90 126 Screw M5 x 25 ...

Page 49: ...A 12 Order No BA 93 20 270 Issue 01 03 08 49 Ceramic tripod complete A 12 93 40 022 ...

Page 50: ...ption Order No Adapter Standard for ARC 80 05 689 Welding with ceramic ferrules Threadedstuds Chuck sleeveswithinternal thread and pins Ø 5 mm e 6 mm 83 50 005 Ø 6 mm e 7 mm 83 50 006 Ø 8 mm e 4 mm 83 52 008 Ø 8 mm e 9 mm 83 50 008 Ø 10 mm e 4 mm 83 52 010 Ø 10 mm e 11 mm 83 50 010 Ø 12 mm e 6 mm 83 52 012 Ø 12 mm e 13 mm 83 50 012 larger Ø on request ...

Page 51: ...4 Ø 5 0 1 0 3 0 8 m m 5 Ø Ø 6 mm 80 31 095 Ø 8 mm 80 31 120 Ø 10 mm 80 31 150 Ø 12 mm MR 80 31 170 Ø 12 mm MD 80 31 205 larger Ø on request Welding with shielding gas for Description Order No Threadedstuds Chuck sleeveswithinternal thread and pins Ø 4 mm e 5 mm 83 51 004 Ø 5 mm e 4 mm 83 51 005 Ø 6 mm e 7 mm 83 51 006 Ø7 1mm e 9 mm 83 51 071 Ø 8 mm e 9 mm 83 51 008 Ø 10 mm e 11 mm 83 51 010 Ø 12 mm ...

Page 52: ... 270 Issue 01 03 08 8 4 Environmentally Admissible Disposal After repair of the welding gun dispose the replaced parts in an environmentally admissible way Used materials Steel Non ferrous metals brass copper Plastics Aluminium ...

Page 53: ...der Device for the automatic stud feeding of welding ele ments Stud welding unit Power unit inclusive welding gun Thyristor Electronic component contactless switch which will let the current only pass through if a control pulse is given to the gate additional electrode Weldingelement A component like a stud bolt pin which is welded to the work piece Welding gun Device to weld welding elements Welding...

Page 54: ...d welding method for metals General DVS0902 Drawn arcstudwelding DVS0903 Capacitor discharge stud welding with tip ignition DVS0904 Instructions for practice Arc stud welding DVS2927 Resistor projection welding and Arc welding of one sided thick plastics coated thin metal sheets Studwelding general DIN EN ISO 4063 Welding and allied processes Nomenclature of processesandreferencenumbers DINISO857 1 Weld...

Page 55: ...ompatiblity EMC requirements Personalsafetyandaccidentprevention DIN EN ISO 20345 Personalprotectiveequipment Safetyfootwear DINEN12477 Protectiveglovesforwelders DIN EN 166 Personal eye protection Specifications DINEN352 1 Hearing protectors General requirements Part 1 Ear Muffs BGV A1 Accident preventionregulation Principlesof prevention BGV A3 Accident preventionregulation Electrical equipmentand...

Page 56: ...3 8 2 2 3 1 3 2 4 5 M 8 8 0 15 0 4 9 9 5 4 0 7 5 6 0 11 0 M 10 13 0 30 0 7 8 19 0 M 12 19 0 53 0 12 0 33 0 M 16 35 0 135 0 22 0 82 0 Steel 4 81 µ 0 18 Rp0 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 weldable All given values are leads for minimum tensile strength and minimum torque o...

Page 57: ...edifrepairoperationsarecarriedoutbyunauthorized persons Warning Unauthorized interference with the stud welding unit as well as unauthorized alteration of the stud welding unit are prohibited and result in complete cancellation of any guarantee and liability claims against HBS Please fill in the serial number Serial number automatic welding head Serial number power unit Serial number welding gun Seria...

Page 58: ... approval by HBS Description of equipment Welding Gun Type A 12 Order No 93 20 270 Serial No Applicable EC guidelines and corresponding standards Low voltage guideline 2006 95 EC DIN EN 60974 1 Arc welding equipment Part 1 Welding power sources EMC guideline 2004 108 EC DIN EN 60974 10 Arc welding equipment Part 10 Electromagnetic compatibility EMC requirements Machine guideline 98 37 EC DIN EN 602...

Page 59: ...___________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ _________...

Page 60: ...________________ 85221 Dachau Germany __________________________ Postfach 13 46 __________________________ 85203 Dachau Germany __________________________ Productdescription __________________________ Serial number __________________________ My opinion criticism complaints indication of malfunction Dateandsignature ___________________________________________ ...

Page 61: ...A 12 Order No BA 93 20 270 Issue 01 03 08 61 Service Support ...

Page 62: ...cting the welding gun 15 control cable 18 control cable connector 16 corrective actions 33 D defective cables 28 delivery 8 13 dirt and dust 42 disposal 40 52 disposal environmentally admissible 52 distance device 31 drawn arc stud welding variations 25 DVS regulations 31 E ear protection 7 22 electrical shock 21 electrical shock risk of 15 17 electrical voltage 9 12 electromagnetic fields 9 entire p...

Page 63: ...properly instructed qualified 7 personnel qualified 7 pipes welding to 28 place of operation 10 plastic housing 18 plug connection 15 power unit 10 53 prestress at installation 30 56 production 7 protection class 14 43 protective apron 22 protective equipment 15 23 protective equipment personal 7 protective gloves 22 protective goggles 7 PT threaded stud 56 punched plates 28 punched plates welding to 28 ...

Page 64: ...pors 22 training according to current standards 7 transportation 7 transportation packaging storage 11 type plate 12 U unauthorized use 7 user qualification required 7 UT pin 56 V vapors toxic 14 W weight 43 weld checking the quality of the 32 welding elements 10 29 37 53 welding elements lot of 29 welding gun 10 53 welding gun cables 16 welding gun support distance device 31 welding gun trigger 18 we...

Page 65: ......

Page 66: ...HBS Bolzenschweiss Systeme GmbH Co KG Felix Wankel Strasse 18 85221 Dachau Germany Phone 49 0 8131 511 0 Fax 49 0 8131 511 100 E mail post hbs info com www hbs info com ...

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