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CD 2301 Order No. BA 92-12-0231A   Issue 05.01.10

31

5.8.1

Visual Inspection

A visual inspection must be carried out with each welding element.

Condition

Possible cause

Corrective actions

Good welded joint
Low spatters around the weld 
without outer 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 charging voltage
-  Increase plunging speed

One-sided weld pool
One-sided spatter collar
Weld pool came out on one side

-  Arc blow effect
-  Unsymmetric ground connection
-  Welding gun put at an angle

-  Take care for symmetrical ground 
   connection
-  Put welding gun vertically to the workpiece

Visual Inspection

5 Stud Welding Procedure

5.8 Checking the Quality of the Weld

Summary of Contents for CD 2301

Page 1: ...CD 2301 Power Unit North America 92 12 0231A Operating Manual 2010...

Page 2: ...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 Web www hbs info com Copyright The information contained herein may not be copied r...

Page 3: ...alfunction 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 w...

Page 4: ...more copies please provide the order number listed in the foot line Importantreminder Dataandinformationhereinwerecollectedwithgreatestcare Althoughwedidourvery besttocorrectlyupdateanyinformationupt...

Page 5: ...Primary Power Supply 15 3 3 Connecting the Welding Gun to the Power Unit 16 3 4 Ground Connection 17 3 5 Change Working Place 17 4 Function 18 4 1 Components of the Power Unit 18 4 2 Keyboard and Dis...

Page 6: ...e Power Unit 38 6 1 Temporary Switching off 38 6 2 Disposal 38 7 Care and Maintenance 39 7 1 Safety Instructions 39 7 2 Regular Maintenance Operations 39 7 3 Tools to be Used 39 7 4 Open the Power Uni...

Page 7: ...ve 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 commence stud wel...

Page 8: ...pter 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 power unit Observe all note...

Page 9: ...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 We...

Page 10: ...mentsaccordingtoactualstandards 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 stud welding unit not used as...

Page 11: ...ly be checked before starting up by visual inspection visible damage The following items are to be observed if the power unit is not to be put into operation immediately after delivery The power unit...

Page 12: ...pe 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 dama...

Page 13: ...12 0231A Issue 05 01 10 13 2 Delivery The basic equipment of your power unit contains the following components No of pieces Part Type OrderNo 1 Power unit CD2301 92 12 0231A 1 Operatingmanual CD2301 B...

Page 14: ...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...

Page 15: ...n the vicinity of the welder Wear your personal protective equipment according to actual standards see appendix 3 2 Connecting the Power Unit to the Primary Power Supply Compare the primary voltage sp...

Page 16: ...In case of loose connection heat may build up in the plug and may destroy the entire plug connection Plug the control cable in the connector of the power unit Twist the retaining nut of the control ca...

Page 17: ...the areas where you intend to connect the ground cables Connect the ground clamps to the work piece as securely as possible Take care to ensure good contact and symmetrical connection The welding loc...

Page 18: ...argingresistor 2 Rectifier 5 Welding thyristor 3 Triac 6 Capacitorbattery Mains alternating current is converted in the rectifier 2 Capacitors 6 are continuously adjustable charged by both the Triac 3...

Page 19: ...31A Issue 05 01 10 19 4 2 Keyboard and Display Stand bydisplaygreen Readyforwelding Stand by display red Charging the capacitor battery How to use displays and keys is described in section 5 6 4 Funct...

Page 20: ...g the actual stud 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 Step onto an insulati...

Page 21: ...ibleclothes 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 an...

Page 22: ...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...

Page 23: ...ement moves to the work piece with a speed of 0 5 to 1 m s The adjusted spring pressure controls the plunging speed of the welding element Higher plunging speed leads to shortened arc time and consequ...

Page 24: ...2 2 position 4 Theweldingelementismovedbythepressurespringtotheworkpiecewithaspeed of 0 5 to 1 5 m s The adjusted spring pressure and the preset lift distance controls the plunging speed of the weldi...

Page 25: ...round clamp connectionareas paint oil and any other impurities rust non conductive coatings from surface treated work pieces Weld to smooth and flat surfaces only For welding to pipes or punched plate...

Page 26: ...m 5 32 8 32 70 6 6 1 4 1 4301 1 4303 M5 5 mm 5 mm M3 3 16 10 32 90 6 6 1 6 1 4301 1 4303 M6 6 mm 6 mm M4 1 4 1 4 20 130 6 6 2 1 4301 1 4303 M8 7 1 mm 7 1 mm M5 5 16 5 16 18 170 11 6 2 1 4301 1 4303 M1...

Page 27: ...er unit with the mains switch The condition of the welding unit is monitored after switching on The display shows three bars and the following parameters are monitored Deviationfromusualchargingtime U...

Page 28: ...ristor is defective in the case of a charging malfunction exceeding the charging period if arrow keys jam when appealing the library mode stud diameter Yellow lights if a welding gun with solenoid is...

Page 29: ...eration of the stud welding unit is LIFE THREATENING The stud welding unit must only be operated by qualified personnel see chapter 1 Observe the safety instructions in chapters 1 3 and 5 Prepare the...

Page 30: ...ng process can only be initiated if the current circuit is closed i e the welding element is in electrical contact with the base material After the welding process has been completed withdraw the weld...

Page 31: ...o 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 in...

Page 32: ...f 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 car...

Page 33: ...ing speed too low Welding element base material combination not suitable Increase charging voltage Increase plunging speed Replace welding element or workpiece Backside deformation Heat input too high...

Page 34: ...ngle 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...

Page 35: ...w er unit is still locked sw itch off the pow er unit inform the reponsible service department If no mentioned actions are successful please contact our service department Instructed personnel Continu...

Page 36: ...of the welding process Threaded stud PT Diameter Length Chuck M3 6 30mm 82 50 003 M4 6 40mm 82 50 004 M5 8 45mm 82 50 005 M6 8 55mm 82 50 006 M8 10 55mm 82 50 008 Materials Mild steel S235 St37 3k 4 8...

Page 37: ...1 1 4303 ISO clip for nails 2 3 Materials Mild steel St2k70 galvanized Stainless steel 1 4301 1 4303 ISO clip for nails plastic coated 3 Material Mild steel St2k70 galvanized Welookforwardtoconsultyou...

Page 38: ...ff 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 Disposal If you shut down the in...

Page 39: ...onents of the power unit periodically of dust Use a dry washcloth or a brush To open the power unit proceed as described in section 7 1 7 3 and 7 4 Clean the surface of the power unit with a humid was...

Page 40: ...emove the cover and disconnect the ground cable on the inside of the cover Now pull off the cover THREAT TO LIFE Check whether the welding capacitors are discharged Measure the voltage with a standard...

Page 41: ...0 mm limited Weldingmaterial Mild steel stainless steel aluminum and brass Welding rate 8 to 20 studs min depending on application and stud dia Capacitance 99 000 F Welding time 1 to 3 msec Energy 2 4...

Page 42: ...M5 x 8 25 1 88 11 785A Rear wall complete 26 16 80 90 158 Screw M4 x 6 black 27 4 80 90 184 Tooth lock washer A4 30 1 80 50 565 Mains cable 35 1 88 11 781B Front plate 36 1 80 90 253 Screw M8 x 25 37...

Page 43: ...CD 2301 Order No BA 92 12 0231A Issue 05 01 10 43 Power unit type CD 2301 92 12 0231A 8 Appendix 8 2 Spare Parts...

Page 44: ...Flat connection 50 1 80 08 793 Resistorsupport 55 2 80 57 037 Resistor 30 R 70 W 60 1 80 57 010 Resistor 10 R 70 W 64 1 80 40 066B Distance stud 65 1 80 56 041 Capacitor 70 1 80 57 332 Resistor L 71 2...

Page 45: ...CD 2301 Order No BA 92 12 0231A Issue 05 01 10 45 Capacitor battery CD 2301 80 30 368A Part 1 8 Appendix 8 2 Spare Parts...

Page 46: ...0 198 Washer 6 mm 110 4 80 90 150 Washer 8 mm 115 1 80 90 274 Washer 17 mm 120 6 80 90 239 Cupal washer M 6 123 2 80 90 167 Cupal washer M 8 145 3 80 90 140 Spring washer 8 mm 150 1 80 90 243 Spring w...

Page 47: ...CD 2301 Order No BA 92 12 0231A Issue 05 01 10 47 Capacitor battery CD 2301 80 30 368A Part 2 8 Appendix 8 2 Spare Parts...

Page 48: ...apacitornoisesuppression 29 2 80 90 137 Screw M3 x 8 30 1 80 30 300 Controlcablesleeve 32 1 80 50 047 Fuse element 33 1 80 50 028 Fine wire fuse 10 AT 35 1 80 50 050 Mains switch 36 1 80 10 837 Dust p...

Page 49: ...CD 2301 Order No BA 92 12 0231A Issue 05 01 10 49 Front plate complete 88 11 781B 8 Appendix 8 2 Spare Parts...

Page 50: ...leconnection 20 1 80 11 441 Lock nut 24 2 80 90 194 Tooth lock washer A3 25 1 80 50 775 Mainsinterferencefilter 27 2 80 90 131 Washer 3 mm 28 2 80 90 190 Spring washer 3 mm 29 2 80 90 165 Nut M 3 31 1...

Page 51: ...CD 2301 Order No BA 92 12 0231A Issue 05 01 10 51 Rear wall complete 88 11 785A 8 Appendix 8 2 Spare Parts...

Page 52: ...g any repair or maintenance operation always switch the power unit off and disconnect the primary plug Do not wear a wrist watch or any electrically conductive jewellery To change the electronic board...

Page 53: ...lace the electronic board For re assembly proceed in reversed sequence Replace the electronic board 80 80 502V3 1 See changing the electronic board 80 80 5034 In addition you must remove the two space...

Page 54: ...special type suits to special type suits to CD 1504 suits to special type suits to special type suits to special type suits to SC 2401 suits to special type suits to special type Switch off the power...

Page 55: ...er position With wrong primary voltage setting the power unit may be damaged Switching the primary voltage may only be carried out by sufficiently qualified personnel or by your service technician Bef...

Page 56: ...56 CD 2301 Order No BA 92 12 0231A Issue 05 01 10 8 3 Circuit Diagram 8 Appendix 8 3 Circuit Diagram...

Page 57: ...8 4 Environmentally Admissible Disposal After repair of the power unit dispose replaced parts in an environmentally admissible way Used materials Steel Nonferrousmetals brass copper Plastics Aluminum...

Page 58: ...feeder 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 p...

Page 59: ...thod 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 a...

Page 60: ...cidentprevention DIN EN ISO 20345 Personalprotectiveequipment Safetyfootwear DINEN12477 Protectiveglovesforwelders DIN EN 166 Personal eye protection Specifications DIN EN 352 1 Hearing protectors Gen...

Page 61: ...Rp0 2 340 N mm2 1 4301 03 A2 50 0 18 Rp0 2 210 N mm2 AlMg3 F23 0 18 Rp0 2 170 N mm2 CuZn37 Ms63 0 18 Rp0 2 250 N mm2 Values correspond with actual standards 1 weldable All given values are leads for m...

Page 62: ...operationsarecarriedoutbyunauthorized persons Warning Unauthorized interference with the stud welding unit as well as unauthorized alteration of the stud welding unit are prohibited and result in comp...

Page 63: ...______ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ __________________________________...

Page 64: ..._____________ 85221 Dachau Germany __________________________ Postfach 13 46 __________________________ 85203 Dachau Germany __________________________ Productdescription __________________________ Se...

Page 65: ...CD 2301 Order No BA 92 12 0231A Issue 05 01 10 65 Service Support Service Support...

Page 66: ...32 cover 40 cross slotted screwdriver 39 D delivery 8 13 display 19 disposal 38 disposal environmentally admissible 57 distance device 30 DVS regulations 29 E ear protection 7 21 electrical shock risk...

Page 67: ...injury 9 personnel properly instructed qualified 7 personnel qualified 7 pin UT 36 pin with internal tread IT 36 pipes welding to 25 place of operation 10 plunging speed 23 24 power unit 58 power unit...

Page 68: ...1 training according to current standards 7 transformer 18 transportation 7 transportation packaging storage 11 triac 18 trigger 19 type plate 12 15 55 U unauthorized use 7 user qualification required...

Page 69: ......

Page 70: ...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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