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A 22 Order No. BA 93-20-290   Issue 01.03.08

Your welding gun may differ in some details from the captions in this manual. This has

no effect on the operation of the welding gun.
Should you have questions about this manual or in case you want to order some more

copies, please provide the order number listed in the foot line.
Important reminder:
Data and information herein were collected with greatest care. Although we did our very

best to correctly update any information up to the time of delivery, there is no guarantee

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-Strasse 18
85221 Dachau / Germany

A feedback blank is provided in the appendix.

Summary of Contents for 93-20-290

Page 1: ...A 22 Welding Gun 93 20 290 Operating Manual...

Page 2: ...e 18 85221 Dachau Germany Phone 49 0 8131 511 0 Fax 49 0 8131 511 100 E mail po hbs info com Web www hbs info com Copyright The information contained herein may not be copied reproduced adapted merged...

Page 3: ...malfunction In case of accident inform a physician and the responsible o cial body THREATTOLIFE Persons tted with a pace maker mu not operate the ud welding machine MAGNETICFIELDS During ud welding r...

Page 4: ...re copies please provide the order number li ed in the foot line Importantreminder Dataandinformationhereinwerecollectedwithgreate care Althoughwedidourvery be tocorrectlyupdateanyinformationuptotheti...

Page 5: ...un to the Power Unit 15 3 3 Ground Connection 16 3 4 Change Working Place 17 4 Function 18 4 1 Components of the Welding Gun Ceramic 18 4 2 Installation of Chuck and Tripod 19 4 3 Adju ment of Plungin...

Page 6: ...witching o the Welding Gun 40 6 1 Temporary Switching off 40 6 2 Disposal 40 7 Care and Maintenance 41 7 1 Safety In ructions 41 7 2 Regular Maintenance Operations 42 8 Appendix 43 8 1 Technical Data...

Page 7: ...he safety in ructions Before arting up the welding gun let the operator sign the con rmation that he she has read and fully under ood the operating manual see appendix Do not commence ud welding until...

Page 8: ...he 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 weldin...

Page 9: ...al mean Threat to life or risk of personal injury Risk of material damage Ban for persons tted with a pace maker Warning of dangerous electrical voltage Warning of electromagnetic elds Wear protective...

Page 10: ...weld welding elements according to actual andards 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...

Page 11: ...can only be checked before arting 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 g...

Page 12: ...isible Type plate The type plate contains the following data Manufacturer Type OrderNo SerialNo Primaryvoltage Fuse Powerconsumption Cooling class Protection class Date Safety symbols Replace illegibl...

Page 13: ...290 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 4 85 m A 22 93 20 290 1 OperatingM...

Page 14: ...regulations of the o cial bodies see appendix Weld only in adequate di ance from combu ible articles or liquids Before you art welding remove any combu ible articles or liquids in vicinity of the work...

Page 15: ...it and mu not ay in its vicinity during welding During the actual welding process you mu expect red hot welding spatters possibly liquid spatters a ash and a loud bang 90 dB A Alert any colleagues who...

Page 16: ...lding gun cables mu not be coiled during welding Coiled cables work as a coil and may negatively a ect the welding result Before welding lay out the cables lengthwise Fix the cables Strong magnetic el...

Page 17: ...metrical connection The welding location mu lie directly between the two ground clamps 3 4 Change Working Place Switch o the power unit In this way you avoid any risk of electrical shock When you move...

Page 18: ...ted Positioned at the front of the welding gun there is the ud chuck where the welding elements of the welding gun are manually fed A tripod with foot piece where the ceramic ferrule holder is inserte...

Page 19: ...uck and Tripod Welding with Ceramic Ferrule Screw the chuck on the thread art of the welding gun and thighten it rmly with a wrench SW 14 17 accessory Put the ud up to the op into the chuck Attention...

Page 20: ...Allan key 5 mm accessory Tighten the tripod legs with an Allan screw 4 3 Adju ment of Plunging Depth Projection Theplungingdepthcharacterizestheoverlapsizewhichwouldbeachievedbywelding elementandbasem...

Page 21: ...tion see section 5 5 4 5 Adju ment of Lift Scale Screw o the cup at the rear Now you can screw in the lift up to the op by turning clockwise Now you can screw out the lift ep by ep by turning counter...

Page 22: ...set lower than in horizontal position also with larger uds There mu be no friction between ud and ceramic ferrule if so center the foot plate of the welding gun When triggering the welding gun key the...

Page 23: ...electrical shock and arc During the actual ud welding process do not touch the ud chuck or retaining nut nor any electrically conductive parts in their vicinity These are all electrically life Step on...

Page 24: ...ds see appendix non combu ibleclothes ear protection to current andards see appendix a protective apron over your clothes a protective headgear when welding overhead Before arting to weld remove all c...

Page 25: ...ers a ash 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 andards see appendix MAGNETIC FIELDS D...

Page 26: ...e appendix The andards 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 pla ic or lique ed condition of t...

Page 27: ...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 we...

Page 28: ...o the weld pool by a formation of metal vapor in the arc chamber abilizes and concentrates the arc thus decreasing the arc blow e ect formsthemeltunderpressuretoa weldcollarandsupportstheweldpoolonave...

Page 29: ...ck the chuck for proper seat see operating manual of according power unit Before welding make sure that the bellows are checked for damage and proper seat 5 4 High Strength Welds The following mu be r...

Page 30: ...cessary For an assessment of welding results see sections 5 7 and 5 8 Determination of welding time Data given in the following table are only guidelines They mu be veri ed by trial welds on the actua...

Page 31: ...ear always your personal protective equipment according to actual andards see appendix Insert the welding element into the chuck As soon as the power unit is ready for the welding process place the we...

Page 32: ...element w ithin tolerance after w elding Correct parameters None Contraction of w eld collar Plunging depth or lift too low Increase plunging depth check lift and centering of the ceramic ring w eldin...

Page 33: ...rections The bending te is passed if a crack or a fracture of the welded zone does not occur Please note the in ructions on fault recognition and corrective actions in chapter 5 You don t need to te a...

Page 34: ...ment 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 Inc...

Page 35: ...ction of the arc It causes a single sided melting of the ud material increased pore formation and undercuts in the weldingarea The arc blow e ect is proportional to the current and can be in uenced by...

Page 36: ...gger In case of no flow Replace control cable Qualified personnel Micro sw itch defective w ith present contact signal on pow er unit Check micro sw itch w ith pressed w elding gun trigger for electri...

Page 37: ...ar care not to mix up di erent lots Slighte variations in geometry of the welding elements especially of the ignition tip require modi ed settings of the welding process Threaded stud RD MR Diameter L...

Page 38: ...eramic M12 20 50 mm 83 50 012 M16 20 50 mm 83 50 016 Materials S235 St37 3k 4 8 1 4301 1 4303 Head stud SD Diameter Length Chuck ceramic 1 2 13 50 175 mm 83 53 012 5 8 16 50 175 mm 83 53 019 3 4 19 50...

Page 39: ...4301 1 4303 Ceramic ferrule UF for head stud SD Diameter Chuck ceramic ferrule 1 2 80 30 213 5 8 80 30 219 3 4 80 30 219 7 8 80 30 222 Materials S235 St37 3k 4 8 1 4301 1 4303 Welookforwardtoconsultyo...

Page 40: ...6 1 Temporary Switching o Switch o the power unit Unplug the control cable and the welding cable from the power unit Protect the ud welding gun again ingress of uids and foreign bodies 6 2 Disposal If...

Page 41: ...provide long life expectancy 7 1 Safety In ructions Let maintenance and repair operations be carried out only by quali ed personnel or by your competent service technician Before you art any maintena...

Page 42: ...nect control cable and welding cable from power unit Clean the surface of the welding gun of dirt and du Do not use any solvent containing cleaning agents Solvent containing cleaning agents may damag...

Page 43: ...0 63 dependingontripod Stud material Mild eel or ainless eel Stud type Any type or shape special chucks if required Lengthadju ment 9 mm 0 35 automatic Stroke Adju ment range 6 mm 0 24 0 25 mm 0 01 ep...

Page 44: ...5 932 Lengthcompensation complete 13 1 80 05 540 Pressurespringforlengthcompensation 15 1 88 15 939 Cap complete 17 1 88 15 943 Plungingdamper 19 1 88 15 944 Liftdamper 21 1 88 15 941 Stativ support c...

Page 45: ...A 22 Order No BA 93 20 290 Issue 01 03 08 45 Welding gun type A 22 ceramic 93 20 290...

Page 46: ...od 10 x 240 complete 93 40 041 for Shear connectors dia 16 to 22 mm Position Quantity OrderNo Description 1 1 80 41 028 Foot piece 5 2 80 40 110 Leg10 240 6 2 80 40 109 Coverplatetripod 11 2 80 10 103...

Page 47: ...od 10 x 390 complete 93 40 074 for Shear connectors dia 16 to 22 mm Position Quantity OrderNo Description 1 1 80 41 028 Foot piece 5 2 80 40 493 Leg10 390 6 2 80 40 109 Coverplatetripod 11 2 80 10 103...

Page 48: ...li ceramic tripod 10 x 390 A 22 1 complete 93 40 073 Position Quantity OrderNo Description 1 1 88 15 824 Foot piece 5 2 80 40 493 Leg10 390 6 2 80 40 109 Coverplatetripod 11 2 80 10 1035 Coverplate 12...

Page 49: ...eveswithinternal thread and pins 12 mm e 13 mm 83 50 012 16 mm e 13 mm 83 50 016 larger on reque Concreteanchorsand head uds 1 2 25 mm e 8 mm 83 53 012 5 8 3 4 32 mm e 12 mm 83 53 019 7 8 35 mm e 12 m...

Page 50: ...2 A 2 2 A 2 2 A 2 2 A A 22 ceramic Ceramic tripod complete PSC2 Ceramic tripod complete PSC2 Ceramic tripod complete PSC2 Ceramic tripod complete PSC2 Ceramic tripod complete PSC2 Stud 4 12 mm 22 mm...

Page 51: ...Issue 01 03 08 51 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...

Page 52: ...der Device for the automatic ud feeding of welding ele ments Stud welding unit Power unit inclusive welding gun Thyri or Electronic component contactless switch which will let the current only pass th...

Page 53: ...welding method for metals General DVS0902 Drawn arc udwelding DVS0903 Capacitor discharge ud welding with tip ignition DVS0904 In ructions for practice Arc ud welding DVS2927 Resi or projection weldi...

Page 54: ...ompatiblity EMC requirements Personalsafetyandaccidentprevention DIN EN ISO 20345 Personalprotectiveequipment Safetyfootwear DINEN12477 Protectiveglovesforwelders DIN EN 166 Personal eye protection Sp...

Page 55: ...1 2 7 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 0 18 Rp0 2 340 N mm2 1 4301 03 A2 50 0 18 Rp0 2 21...

Page 56: ...lledifrepairoperationsarecarriedoutbyunauthorized persons Warning Unauthorized interference with the ud welding unit as well as unauthorized alteration of the ud welding unit are prohibited and result...

Page 57: ...approval by HBS Description of equipment Welding Gun Type A 22 Order No 93 20 290 Serial No Applicable EC guidelines and corresponding andards Low voltage guideline 2006 95 EC DIN EN 60974 1 Arc weldi...

Page 58: ...__________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ _____...

Page 59: ...______________ 85221 Dachau Germany __________________________ Po fach 13 46 __________________________ 85203 Dachau Germany __________________________ Productdescription __________________________ Se...

Page 60: ...60 A 22 Order No BA 93 20 290 Issue 01 03 08 Service Support...

Page 61: ...ns 42 cold formed process 37 company speci c maintenance in ruction 7 company speci c work order 7 components of the welding gun 18 concrete anchors and head uds 49 con rmation 58 con rmation operator...

Page 62: ...of 7 operation improper 31 operators 7 order number 13 44 46 47 48 ordering spare parts 44 56 P pace maker 9 15 25 packaging 11 personal injury 9 personnel 7 personnel properly in ructed quali ed 7 p...

Page 63: ...F 55 threaded uds with ange FD 55 threaded uds with reduced shaft RD RF 55 threat to life 8 thyri or 52 torque 30 55 toxic vapors 24 training according to current andards 7 transportation 7 transporta...

Page 64: ...64 A 22 Order No BA 93 20 290 Issue 01 03 08...

Page 65: ......

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

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