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IT 1002 Order No. BA 93-66-1202   Issue 01.06.08

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 93-66-1202

Page 1: ...IT 1002 Power Unit Ceramic Gas Version 93 66 1202 Operating Manual...

Page 2: ...rasse 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 me...

Page 3: ...of 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...

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

Page 5: ...ting the Welding Gun to the Power Unit 18 3 4 Ground Connection 19 3 5 Shielding Gas Connection 20 3 6 Change Working Place 20 4 Function 21 4 1 Components of the Power Unit 21 4 1 1 Power Unit 21 4 1...

Page 6: ...g the Quality of the Weld 38 5 8 1 Visual Inspection 38 5 8 2 Bending Test 39 5 8 3 Arc Blow E ect 41 5 9 Malfunctions and Corrective Actions 42 5 10 Welding Elements 43 6 Switching o the Power Unit 4...

Page 7: ...IT 1002 Order No BA 93 66 1202 Issue 01 06 08 vii Glossary 64 Regulations and Standards 65 Further In ructions 67 Guarantee Clauses 68 Con rmation 69 Feedback 70 Service Support 71 Index 72...

Page 8: ...viii IT 1002 Order No BA 93 66 1202 Issue 01 06 08...

Page 9: ...t Strictly observe the safety instructions Before starting up the power unit let the operator sign the confirmation that he she has read and fully understood the operating manual see appendix Do not c...

Page 10: ...ff the Power Unit in Chapter 6 Care and Maintenance 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 p...

Page 11: ...nual 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 protecti...

Page 12: ...welding elements according to actual standards seechapter5andappendix Anyotheruseisregardedasnotusedasdirected The manufacturer is not liable for damages resulting from the stud welding unit not used...

Page 13: ...oningofthepowerunitcanonlybecheckedbeforestarting upbyvisual inspection visible damage Thefollowingitemsaretobeobservedifthepowerunitisnottobeputintooperation immediately after delivery The power unit...

Page 14: ...y visible Type plate The type plate containsthe followingdata Manufacturer Type OrderNo SerialNo Primaryvoltage Fuse Powerconsumption Cooling class Protection class Date Safety symbols Replace illegib...

Page 15: ...No BA 93 66 1202 Issue 01 06 08 15 2 Delivery Thebasicequipmentofyourpowerunitcontainsthefollowingcomponents No of pieces Part Type Order No 1 Powerunit IT 1002 93 66 1202 1 OperatingManual IT 1002 B...

Page 16: ...le 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 t...

Page 17: ...leagues who are occupied in the vicinity of the welder Wear your personal protective equipment according to actual andards see appendix 3 2 Connecting the Power Unit to the Primary Power Supply Compar...

Page 18: ...that they are properly locked In case of loose connection heat may build up in the plug and may de roy the entire plug connection Plug the control cable in the connector of the power unit Twist the r...

Page 19: ...egularly to ensure that they are properly locked In case of loose connection heat may build up in the plug and may de roy the entire plug connection Remove any rust paint or contaminants from the work...

Page 20: ...8 16 liters min Minimum ow rate for ud welding with shielded gas is 8 l min Agasmixtureof82 Argon Ar and18 carbondioxide CO 2 ismainlyusedforstud welding 3 6 Change Working Place Switch o the power u...

Page 21: ...capacitors 9 Welding current stabilizer 5 Control unit Afterpassingthemainsswitch 1 andtheEMC filter 2 themainsalternatingcurrent is converted in the bridge rectifier 3 The rectified voltage is smooth...

Page 22: ...l unit synchronizes the mechanical sequence lifting the welding element withtheelectroniccontrol ignitionofpilotarc ignitionofmainarc sequenceofwelding time The welding time is stepless adjustable 4 2...

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

Page 24: ...ards see appendix non combu ible clothes ear protection to current andards see appendix a protective apron over your clothes a protective headgear when welding overhead Before arting to weld remove al...

Page 25: ...ters 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...

Page 26: ...endix Drawn Arc Stud Welding The HBS stud welding unit operates by process of arc stud welding with drawn arc ignition accordingtothecurrentstandards seeappendix Thestandardsassignthis method of joini...

Page 27: ...on and adjustment values are based on the use of welding elements which correspond with current standards see appendix Variations on Drawn Arc Stud Welding Item Drawn arc stud welding with ceramic fer...

Page 28: ...mospherefromgettingtotheweldpoolbyaformationofmetalvaporin thearcchamber stabilizes and concentrates the arc thus decreasing the arc blow effect formsthemeltunderpressuretoaweldcollarandsupportsthewel...

Page 29: ...r 99 99 DIN EN ISO 14175 I1 or Ar He mixtures DIN EN ISO 14175 I3 are used Theshieldinggasinfluences thearcandthemeltingbehaviorofweldingelementandworkpiece thedevelopmentoftheweldcollarandthepenetrat...

Page 30: ...lementswithflange accordingtocurrentstandards seeappendix areused whichformsalargerweldingareacomparedwiththeshaftdiameter Inthis way highertensionalforcesthaninthestudshaftcanbetransmittedinspiteofso...

Page 31: ...emoved both from the weld zone and the ground clamp connection areas paint oil and any other impurities rust non conductive coatings from surface treated workpieces Weld to smooth and flat surfaces on...

Page 32: ...dized M5 3 16 6 1 4 600 100 M6 1 4 5 4 0 21 432 108 M6 1 4 7 0 28 700 110 M8 5 16 7 2 0 28 576 144 M8 5 16 9 0 35 900 140 M10 3 8 9 0 35 720 180 M10 3 8 11 0 43 1000 190 M12 1 2 10 9 0 43 872 218 M12...

Page 33: ...mbinations see appendix and operating manual of the according welding gun 5 6 Switching on the Power Unit Improper operation of the ud welding unit is LIFE THREATENING Fir read the safety in ructions...

Page 34: ...workpiece Red on power unit is locked after welding until there is electrical contact with the workpiece Green on power unit is ready for welding Red on power unit is locked if the power unit is overh...

Page 35: ...foretheweldingprocessstarts The gas flows automatically until the welding gun is removed from the joined welding element Adjust the flow meter at the gas bottle to 8 to 16 liters min minimum 8 l min P...

Page 36: ...o the pre selected welding current In addition you can modify the welding time and welding current individually by pressing the arrow keys as described above If you are working with shielding gas diff...

Page 37: ...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 weldi...

Page 38: ...ing 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 e...

Page 39: ...gtestispassedifacrackorafractureoftheweldedzonedoesnotoccur Please note the instructions on fault recognition and corrective actions in chapter 5 You don t need to te all uds It is su cient to carry o...

Page 40: ...lement 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 I...

Page 41: ...fthearc Itcausesasingle 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 symmetr...

Page 42: ...or electrical flow w ith triggered start button Replace w elding gun trigger button Qualified personnel Control cable broken Check control cable for electrical flow Replace control cable Qualified per...

Page 43: ...ramic 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 S...

Page 44: ...51 010 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 5...

Page 45: ...0 222 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...

Page 46: ...y 6 1 Temporary Switching o Switch off the power unit Unplug the control cable and the welding cable from the power unit Protect the power unit against ingress of fluids and foreign bodies 6 2 Disposa...

Page 47: ...ug Do not wear a wri watch or any electrically conductive jewellery 7 2 Regular Maintenance Operations Clean the inner components of the power unit periodically of du Use a dry washcloth or a brush To...

Page 48: ...ed in repairing electrical equipment Remove the 14 screws of the casing 5 at each side and 4 on top of casing cover Carefully remove the cover and disconnect the ground cable on the inside of the cov...

Page 49: ...ss steel aluminum Weldingrate 1 2 M12 25 studs min Weldingcurrent 1 000A Currentadjustmentrange Stud welding 100 to 1 000 A electrode 50 to 400 A stepless Welding time 5 to 1 000 msec stepless Primary...

Page 50: ...67 Sh ieldinggasmodule 13 1 88 13 180 Cover 15 1 80 10 1139 Label mat black 17 2 88 10 546 Coverplate 19 1 80 10 857 HandleA 300 31 1 80 10 159 Cap 33 2 80 10 115 Cap 35 1 80 11 359 Conductor mark 37...

Page 51: ...IT 1002 Order No BA 93 66 1202 Issue 01 06 08 51 Power unit IT 1002 93 66 1202...

Page 52: ...ationplate 3 1 88 13 164 Frontfilmoperationplate 31 1 80 80 558 Electronicboard 35 4 80 11 987 Distancesleeve 39 4 80 11 415 Distance stud 41 2 80 11 111 CagenutM4 43 1 80 11 121 Flatconnection 45 1 8...

Page 53: ...IT 1002 Order No BA 93 66 1202 Issue 01 06 08 53 Front plate complete IT 1001 IT 1002 88 13 163...

Page 54: ...7 P C board 39 1 80 56 041 Capacitor 41 1 80 57 332 Resistor L 43 1 80 40 066 Distance stud 51 4 80 11 989 Distance stud M4 55 1 80 11 670 Cable mounting 70 1 80 10 332 Adhesive clip 71 1 80 70 341 Co...

Page 55: ...IT 1002 Order No BA 93 66 1202 Issue 01 06 08 55 Supply module complete IT 1002 88 17 997...

Page 56: ...1002 88 13 167 Pos Quantity Order No Designation 100 1 80 10 145 Connector female 110 1 80 10 0916 Swivelconnection 112 1 80 10 167 Screwing 115 1 80 10 240 Connector male 120 1 80 10 146 Solenoidvalv...

Page 57: ...IT 1002 Order No BA 93 66 1202 Issue 01 06 08 57 Shielding gas module IT 1001 IT 1002 88 13 167...

Page 58: ...1 5 41 1 80 50 480 Primary switch 43 1 80 50 041 Controlcablesleeve 44 1 80 10 0173 Clip onferrite 45 2 80 11 111 Cage nut M4 47 4 80 10 576 Flatconnection 48 2 80 56 215 Capacitor 49 1 80 11 121 Fla...

Page 59: ...IT 1002 Order No BA 93 66 1202 Issue 01 06 08 59 Terminal plate complete IT 1002 88 18 013...

Page 60: ...mark 53 3 80 11 359 Conductor mark 60 1 80 11 669 Wire protecting sleeve 70 2 80 10 050 Flat connection 71 4 80 90 173 Screw M4 x 10 72 1 80 90 404 Screw M4 x 25 73 4 80 90 191 Screw M4 x 8 75 2 80 90...

Page 61: ...IT 1002 Order No BA 93 66 1202 Issue 01 06 08 61 Power unit complete IT 1002 88 17 929...

Page 62: ...62 IT 1002 Order No BA 93 66 1202 Issue 01 06 08 8 3 Electrical Circuit Diagram...

Page 63: ...93 66 1202 Issue 01 06 08 63 8 4 Environmentally Admissible Disposal Afterrepairofthepowerunit disposereplacedpartsinanenvironmentally admissible way Used materials Steel Nonferrous metals brass coppe...

Page 64: ...feeder Device for the automatic stud feeding of welding elements Stud welding unit Power unit inclusive welding gun Thyristor Electronic component contactless switch which will let the current only p...

Page 65: ...rials DVS0901 Studweldingmethodformetals Survey DVS0902 Arc stud welding DVS0903 Capacitordischargeweldingwithtipignition DVS0904 Tips Arc stud welding DVS2927 ResistorprojectionweldingandArcweldingof...

Page 66: ...Part 10 Requirements Personalsafetyandaccidentprevention DINENISO20345 Personalprotectiveequipment Safetyfootwear DINEN12477 Protectiveglovesforwelders DINEN166 Personaleye protection Specifications...

Page 67: ...7 3 8 2 2 3 1 3 2 4 5 M8 8 0 15 0 4 9 9 5 4 0 7 5 6 0 11 0 M10 13 0 30 0 7 8 19 0 M12 19 0 53 0 12 0 33 0 M16 35 0 135 0 22 0 82 0 Steel 4 8 1 0 18 Rp0 2 340 N mm 2 1 4301 03 A2 50 0 18 Rp0 2 210 N mm...

Page 68: ...ncelledifrepairoperationsarecarriedoutbyunauthorized persons Warning Unauthorized interference with the ud welding unit as well as unauthorized alteration of the ud welding unit are prohibited and res...

Page 69: ..._____________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ __...

Page 70: ..._________________ 85221 Dachau Germany __________________________ Po fach 13 46 __________________________ 85203 Dachau Germany __________________________ Productdescription __________________________...

Page 71: ...IT 1002 Order No BA 93 66 1202 Issue 01 06 08 71 Service Support...

Page 72: ...er 47 D defective cables 31 delivery 10 15 display 22 disposal 46 disposal environmentally admissible 63 di ance device 37 drawn arc ud welding variations 27 DVS regulations 37 E ear protection 9 24 e...

Page 73: ...eration 12 power unit 21 64 pre ress at in allation 33 67 primary power supply 17 production 9 protective apron 24 protective equipment 17 25 protective equipment personal 9 protective gloves 24 prote...

Page 74: ...izeduse 9 userqualification required 9 V vapors toxic 16 visualinspection 38 W weld checking the quality of the 38 weldingelement 64 weldingelements 12 32 43 weldingelements lot of 32 weldinggun 12 64...

Page 75: ......

Page 76: ...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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