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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

22

9 Welding Process

 

–

The weld pool solidifies and the welding element is physically connected to the 

workpiece.

 

–

The time period between ignition of the arc and solidification of the weld pool is 

about 3 ms.

 

– The use of contact welding for rapidly oxidizing materials like aluminium and alu-

minium alloys is not recommended because the arcing period with contact welding 

is longer than with gap stud welding.

Summary of Contents for ACCU-TWIN 92-10-2280

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 ACCU TWIN Power Unit 92 10 2280 2013...

Page 2: ...bs info com Web www hbs info com ACCU TWIN Operating Manual Issue 2013 09 Order No E BA 92 10 2280 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: ...7 Warranty 16 8 Components of the Power Unit 17 8 1 Main Assemblies 17 8 2 Keyboard and Display 19 8 3 LED Display 20 8 4 Light emitting diodes LED on the external power supply unit 20 9 Welding Proce...

Page 5: ...out Visual Inspection 34 13 2 Carrying out Bending Test 35 13 3 Blowing Effect and Remedies 37 14 Troubleshooting 38 15 Shutting Down 39 16 Maintenance and Care 40 16 1 Cleaning 40 Maintenance of Acc...

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 ele...

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: ...the electrical energy for stud welding Rectifier Electrical component that converts alternating vol tage into direct voltage Stud feeder Device for automatic feeding of welding elements Stud welding u...

Page 12: ...ng parts No of pieces Part Type Order No 1 Power unit ACCU TWIN 92 10 2280 1 External power supply unit 88 21 490 1 Shoulder strap ACCU TWIN 88 20 911 1 Socket wrench AF 13 80 41 032 1 Operating manua...

Page 13: ...ole or in part only with the approval of the manufacturer 4 Accessories 4 Accessories For example Part Order No Clamping nut 80 05 454 Chuck 82 55 003 Spark protection 80 08 124A Accumulator 80 50 110...

Page 14: ...in welds per minute Capacitance 80 000 F Energy 325 Ws Charging voltage Max 90 V Power source Capacitor Capacitor charging time Approx 30 sec Battery 12 V 5 Ah discharge proof Battery capacity 200 twi...

Page 15: ...exclusively for stud welding of standardised welding elements Any other use will result in the desired strength of the welded joint being reduced The intended use also implies compliance with the inte...

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: ...t 1 the welding capacitors 3 are loaded to the set voltage The capacitors store the energy which is required for the welding process The electronic switch 4 releases the charging voltage in the right...

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: ...welding unit is monitored after activation The current version number of the software is displayed The following variables are then captured battery status thyristor defect charging time of capacitors...

Page 20: ...locked if battery is defective if thyristor is defective in the case of a charging malfunction exceeding the charging period Yellow if there is electrical contact between both chucks 8 4 Light emitti...

Page 21: ...capacitors of the power unit are discharged Because of the high discharge current the ignition tip evaporates explosion like The air gap between welding element and workpiece is ionized see figure po...

Page 22: ...solidifies and the welding element is physically connected to the workpiece The time period between ignition of the arc and solidification of the weld pool is about 3 ms The use of contact welding for...

Page 23: ...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 24: ...through the housing of 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...

Page 25: ...For this purpose remove the spark protection from the two chucks Release the lower clamping nut with a 13 mm socket wrench Adjust the spacing of the chucks in accordance with the welding job see figur...

Page 26: ...ame mains voltage as that indicated on the type plate Compare the current consumption indicated on the type plate with the fuse of your mains power supply Check that the power unit is switched off Onl...

Page 27: ...in in the vicinity of the stud welding unit during welding Never operate the stud welding unit if persons with heart pacemakers are in the vicinity Strong electromagnetic fields are produced in the vi...

Page 28: ...g 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 damage due to electric power or electro magneti...

Page 29: ...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 30: ...onto the workpiece as soon as the power unit is ready for the welding process Press the welding gun firmly with both hands against the workpiece until the welding gun attachment spacer is resting unif...

Page 31: ...d on after approx 30 minutes the sleep mode is started the internal energy consumption is reduced After approx 60 minu tes the power unit will be switched off After automatic switch off switch off the...

Page 32: ...tch on the back of the power unit From safety reasons charging the capacitors is carried out exclusively after withdra wal of the welding gun from the welded welding elements If you want to weld only...

Page 33: ...accumulator can reach up to 200 charging cycles With increased age the charging capacity of the accumulator decreases i e the accumulator is very quick recharged and on the other hand discharged afte...

Page 34: ...nd a bending test The number and type or method of the tests to be performed and the acceptance criteria are defined in the respective standards for the quality demands 13 1 Carrying out Visual Inspec...

Page 35: ...ple and as a check for the selected welding parameters The welded joint is stressed by bending in a non defined way 1 Welding element 2 Welded joint Place the bending device on the welding ele ment 1...

Page 36: ...andom Bending Test Type of fracture Possible cause Corrective actions Base material buckling Correct parameters none Fracture in welding element above flange Correct parameters none If the strength of...

Page 37: ...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 38: ...w Measure accumulator voltage Replace accumulator Trained personnel Accumulator is not charged External power supply unit defective Examine external power supply unit Replace external power unit Train...

Page 39: ...l rights reserved Reprinting in whole or in part only with the approval of the manufacturer 15 Shutting Down 15 Shutting Down Switch off the power unit Protect the power unit and its components agains...

Page 40: ...your dealer or your maintenance department 16 1 Cleaning Clean the surface of the power unit with a slightly damp cloth when ne cessary Add a little household detergent to the cleaning water Do not u...

Page 41: ...dically all 6 months as it will discharge itself at approximately 5 per month Maintenance Instructions for Chucks After the welding process has been completed withdraw the welding gun straight back fr...

Page 42: ...spect the condition of the connecting cable between external po wer supply unit and power unit Inform your dealer or maintenance department if you discover any dama ge Check whether the readings on th...

Page 43: ...ce and Care 16 3 Replacing the Accumulator Loosen the four screws on the rear wall Remove the rear wall Carefully remove the accumulator from the casing Remove the connections from the accumulator Rep...

Page 44: ...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 Rel...

Page 45: ...llowing further EU Directives including changes to the Directives to be applied at the moment of this declaration Low voltage guideline 2006 95 EG EMC guideline 2004 108 EG Directive on the restrictio...

Page 46: ...led 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...

Page 47: ...3 fire hazard 7 form Service Support 38 46 full ear hearing protectors 8 fumes harmful to health 7 23 fuse 26 G gap stud welding 22 glossary 11 goggles with visor 8 H hazards for the machine 9 hazards...

Page 48: ...ge temperature 44 stud counter 19 stud feeder 11 stud welding machine 11 substances explosive 23 surface of base material 36 surface of welding element 36 switching on the power unit 27 symbols used 9...

Page 49: ......

Page 50: ...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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