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82

CDM 3201 Order No. BA 92-12-3321A   Issue 19.09.08

Machine safety

73/23/EWG

Electrical equipment designed for use within
certain voltage limits

2004/108/EG

EMC-Guidelines

98/37/EG

Machine guidelines

DIN EN 60204-1

Safety of machinery - Electrical equipment of
machines - Part 1: General requirements

DIN EN 60529

Degrees of protection provided by enclosures (IP
code)

DIN EN 60974-1

Arc welding equipment - Part 1: Welding power
sources

DIN EN 60974-10

Electromagnetic compatibility (EMC); Arc
welding equipment - Part 10: Requirements

Personal safety and accident prevention

DIN EN ISO 20345

Personal protective equipment:

Safety footwear

DIN EN 12477

Protective gloves for welders

DIN EN 166

Personal eye-protection - Specifications

DIN EN 352-1

Hearing protectors - General requirements -
Part 1: Ear-muffs

BGV A1

Safety rules „Principles of prevention“

BGV A3

Accident prevention regulation „Electrical
equipment and operating material“

BGV B3

Safety rules “Noise”

BGV B11

Safety rules “EMC”

BGV D1

Safety rules - welding, cutting and similar
processes

Please note that in your country additional standards and safety
conditions (especially rules for accident prevention) may differ
from the standards mentioned in this operating manual.

Regulations and Standards

Summary of Contents for CDM 3201

Page 1: ...CDM 3201 Power Unit Automatic Version 92 12 3321A Operating Manual...

Page 2: ...trasse 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...

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: ...e more copies please provide the order number listed in the foot line Importantreminder Dataandinformationhereinwerecollectedwithgreatestcare Althoughwedidourvery besttocorrectlyupdateanyinformationup...

Page 5: ...onnecting the Welding Gun to the Power Unit 18 3 4 Ground Connection 19 3 5 Compressed Air Connection for Automatic Stud Feeding 20 3 6 Change Working Place 20 4 Function 21 4 1 Components of the Powe...

Page 6: ...5 7 3 Charging Monitoring Ready 45 5 7 4 Contact 45 5 7 5 RS232 Interface 45 5 8 Checking the Quality of the Weld 46 5 8 1 Visual Inspection 46 5 8 2 Bending Test 47 5 8 3 Arc Blow Effect 49 5 9 Malf...

Page 7: ...01 Order No BA 92 12 3321A Issue 19 09 08 vii Table of Contents Glossary 80 Regulations and Standards 81 Further Instructions 83 Guarantee Clauses 84 Confirmation 85 Feedback 86 Service Support 87 Ind...

Page 8: ...viii CDM 3201 Order No BA 92 12 3321A Issue 19 09 08 Table of Contents...

Page 9: ...ty 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 welding until...

Page 10: ...apter 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 not...

Page 11: ...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 W...

Page 12: ...tsaccordingtoactualstandards 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 di...

Page 13: ...only be checked before starting up by visual inspection visibledamage The following items are to be observed if the power unit is not to be put into operation immediatelyafterdelivery The power unit m...

Page 14: ...ype 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 dam...

Page 15: ...3321A Issue 19 09 08 15 2 Delivery The basic equipment of your power unit contains the following components No of pieces Part Type Order No 1 Power unit CDM3201 92 12 3321A 1 Operating Manual CDM 3201...

Page 16: ...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 17: ...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 18: ...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 19: ...e that they are properly locked In case of loose connection heat may build up in the plug and may destroy the entire plug connection Remove any rust paint or contaminants from the workpiece in the are...

Page 20: ...e set with the pressure reduction valve of the feeding unit The filter unit cleans and drains the compressed air Rear view 3 6 Change Working Place Switch off the power unit In this way you avoid any...

Page 21: ...irect current in the rectifier 1 Welding capacitors 3 are charged to the adjusted voltage The capacitors store the energy which is required for the welding process The total energy is set by the user...

Page 22: ...al is the interface with the user You are provided with information about the state of the power unit via the display You can program the power unit with the keys according to your requirements How to...

Page 23: ...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 24: ...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 25: ...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 26: ...s to the workpiece with a speed of 0 5 to 1 m s The adjusted spring force controls the plunging speed of the weldingelement Higher plunging speed leads to shortened arc time and consequently to lower...

Page 27: ...position 4 Theweldingelementismovedbythepressurespringtotheworkpiecewithaspeed of 0 5 to 1 5 m s The adjusted spring force and the preset lift distance controls the plunging speed of the welding eleme...

Page 28: ...he ground clamp connectionareas paint oil and any other impurities rust non conductivecoatingsfromsurfacetreatedworkpieces Weld to smooth and flat surfaces only For welding to pipes or punched plates...

Page 29: ...6 6 1 4 1 4301 1 4303 M5 5 mm 5 mm M3 3 16 10 32 80 120 6 6 1 6 1 4301 1 4303 M6 6 mm 6 mm M4 1 4 1 4 20 100 160 6 6 2 1 4301 1 4303 M8 7 1 mm 7 1 mm M5 5 16 5 16 18 140 220 11 6 2 1 4301 1 4303 M10...

Page 30: ...ocket Switch on the power unit with the mains switch Theconditionoftheweldingmachineispermanentlymonitoredafterswitchingon The followingparametersarerecorded Deviation of common charging time Unittemp...

Page 31: ...acitorsarecharged z READY power unit is ready for welding CONTACT there is electrical contact between stud and work piece TRIGGER welding gun button is triggered SOLENOID a drawn arc welding gun is co...

Page 32: ...rocess sequence control Language Selectionoflanguage Welding gun Lift test of drawn arc welding gun Service Time and date setting Reset Reset to HBS standard settings Thyristor Capacity switch CDM 240...

Page 33: ...to Automatic On Blow time xxx mS select the menu item blow time Set the blow time with the keys or 5 6 3 Adjusting the Modes You can select between program and library mode Program mode In program mo...

Page 34: ...ncrease diameter with decrease diameter with Diameters M3 M4 M5 M6 M8 Selection of material Press the arrow key until the sign points to the material M5 AlMg3 130 V select material with or Materials S...

Page 35: ...isstoredinthemicro controller Thissystem of process monitoring does not require any special welding guns and or additional measurementcables During welding the reference part the micro controller dete...

Page 36: ...lds You can define a tolerance range by limiting the max deviation of the weld values compared to the weld PAF values sequence 1 2 Ref Input The PAF value was determined through previous welds and can...

Page 37: ...al entry increase tolerance range With the arrow key you change the position decrease tolerance range With and you can enter 1 small tolerance range the individual digits high sensitivity Reference z...

Page 38: ...s are inside or outside the tolerance range Press the enter key the Press the enter key the following menu is displayed following menu is displayed Ref 8 46776 With the setting Reference With a manual...

Page 39: ...Gun In this menu item you can test the functionality of your welding gun CA 08 During the test the welding gun is triggered as with normal welding sequence but the welding current is not released A w...

Page 40: ...osition of the cursor Use and to entertheindividualnumbers Confirm with the enter key the following menu is again displayed Date Time End With the arrow key switch over to the button End 5 6 8 Adjusti...

Page 41: ...and 2400 Ws Press the arrow key until the sign is displayed in front of Thyristor Gun Service Reset Thyristor with the Enter key open menu item Thyristor with or select Thyristor 1 or THYRISTOR Mode...

Page 42: ...rsonal 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 vertic...

Page 43: ...Stud diameter Order number VBZ 3 3 94 66 103B 4 94 66 104B 5 94 66 105B 5 x mas tree stud 94 66 153B 6 94 66 106B 6 x mas tree stud 94 66 163B 7 1 94 66 171B 8 94 66 108B other on request Put the air...

Page 44: ...e power unit into a PLC stud welding system an additional external weldingstartisprovidedattherearsideofthepowerunit controlsleeve4poles Pin 2 3 The input is designed for 24 V DC control units signal...

Page 45: ...7 5 RS232 Interface Via the serial interface of the power unit the actually recorded data can be output for a potential storage in ASCII format A data cable is required which can be ordered as a cons...

Page 46: ...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...

Page 47: ...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...

Page 48: ...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 49: ...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 50: ...cable broken Check welding gun cable Replace welding gun cable Qualified personnel No display Defective connecting line of welding gun Check function of connecting line Replace connecting line Qualifi...

Page 51: ...S service 8 08 9 Charging control Charge discharge control defective Switch off the unit switch on after approx 5 minutes if error is still present contact HBS service 10 Time Out weld proc Time out d...

Page 52: ...elements especially of the ignition tip require modified settings of the welding process Threaded stud PT Diameter Length Stud M3 6 30mm 82 50 003 M4 6 40mm 82 50 004 M5 8 45mm 82 50 005 M6 8 55mm 82...

Page 53: ...clips for nails 2 3 Materials St2k70 galvanized 1 4301 1 4303 ISO clips for nails plastic coated 3 Material St2k70galvanized Welookforwardtoconsultyouwithviewtospecialweldingelementsandotherspecial ma...

Page 54: ...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 55: ...onents of the power unit periodically of dust Use a dry washcloth or a brush To open the power unit proceed as described in sections 7 1 7 3 and 7 4 Clean the surface of the power unit with a humid wa...

Page 56: ...t only if you are sufficiently qualified in repairing electrical equipment Remove the 14 screws of the casing 5 at each side and 4 on top Carefully remove the cover and disconnect the ground cable on...

Page 57: ...s are discharged Measure the voltage with a commonly used voltmeter Measurement range direct current DC The displayed voltage must be below 10 V Re assemble the power unit in reverse sequence Make sur...

Page 58: ...um and brass Welding rate 12 to 40 studs min depending on application and stud dia Capacitance 132 000 F 66 000 F Welding time 1 to 3 msec Energy 3 200 Ws 1 600 Ws Chargingvoltage 50 to 220 V stepless...

Page 59: ...1 80 11 754 HBS logo small 37 x 28 15 1 80 50 565 Mains cable 30 1 88 10 547 Railconnection 32 1 80 70 382 Connection cable 1 34 1 80 70 383 Connection cable 2 38 2 80 10 159 Cap 67 1 88 17 297 Dista...

Page 60: ...m 139 4 80 90 289 Screw M4 x 12 143 1 80 11 359 Conductor mark ground cable 1 88 13 032 Connectingcable 2 88 13 038 Connectingcable 1 88 10 710 Connectioncable 1 88 11 431 Connectioncable 1 88 11 432...

Page 61: ...CDM 3201 Order No BA 92 12 3321A Issue 19 09 08 61 Power unit type CDM 3201 92 12 3321A 8 Appendix 8 2 Spare Parts...

Page 62: ...0 40 384 Clampingplate 40 4 80 90 168 Screw M5 x 35 42 4 80 90 128 Spring washer 5 mm 45 4 80 90 151 Screw M6 x 16 47 4 80 90 198 Washer 6 mm 50 4 80 90 245 Locking washer 6 mm 52 4 80 90 239 Cupal wa...

Page 63: ...CDM 3201 Order No BA 92 12 3321A Issue 19 09 08 63 Capacitor battery 1 CDM 3201 80 30 230 8 Appendix 8 2 Spare Parts...

Page 64: ...90 128 Spring washer 5 mm 85 3 80 90 151 Screw M6 x 16 87 1 80 90 363 Screw M6 x 18 90 3 80 90 198 Washer 6 mm 92 1 80 90 148 Washer 6 mm 95 4 80 90 245 Locking washer 6 mm 100 4 80 90 239 Cupal wash...

Page 65: ...CDM 3201 Order No BA 92 12 3321A Issue 19 09 08 65 Capacitor battery 2 CDM 3201 80 30 232 8 Appendix 8 2 Spare Parts...

Page 66: ...80 80 516 P C board equipped 39 1 80 80 446 P C board equipped 41 1 80 80 508 P C board 42 1 80 50 955 Battery 44 11 80 11 401 Cablemounting 48 4 80 11 518 Distance stud 49 1 80 80 506 P C board 52 2...

Page 67: ...CDM 3201 Order No BA 92 12 3321A Issue 19 09 08 67 Control insert complete CDM 3201 80 30 270 8 Appendix 8 2 Spare Parts...

Page 68: ...1 80 10 139 Connectormale 45 1 80 10 143 Connectorfemale 50 2 80 90 262 Screw M4 x 30 55 2 80 90 164 Washer 4 mm 70 1 88 13 014 Connectioncable 80 1 88 12 988 Connectioncable 85 1 80 80 570 P C board...

Page 69: ...CDM 3201 Order No BA 92 12 3321A Issue 19 09 08 69 Adaptive control module CDM 3201 92 50 029 8 Appendix 8 2 Spare Parts...

Page 70: ...o Description 1 1 88 10 104 Terminalplate 21 2 80 50 035 Mountingsleeve 23 1 80 30 193 Controlcablesleeve 25 1 80 11 440 Cablescrewing 27 1 80 11 441 Lock nut 31 2 80 10 576 Flat connection 33 2 80 56...

Page 71: ...CDM 3201 Order No BA 92 12 3321A Issue 19 09 08 71 Terminal plate complete CDM 3201 88 13 881 8 Appendix 8 2 Spare Parts...

Page 72: ...Flat connection M4 95 10 80 11 111 Cage nut M4 101 11 80 90 164 Washer 4 mm 102 2 80 90 202 Washer 5 mm 103 13 80 90 121 Spring washer 4 mm 105 3 80 90 128 Spring washer 5 mm 110 8 80 90 153 Nut M4 11...

Page 73: ...CDM 3201 Order No BA 92 12 3321A Issue 19 09 08 73 Module bottom plate complete CDM 3201 88 14 079 8 Appendix 8 2 Spare Parts...

Page 74: ...ction 5 6 4 Any data can individually be processed in the window Microsoft Hyper Terminal Link the data cable HBS order no 80 70 308 to the serial sleeve of the power unit and to the serial sleeve com...

Page 75: ...Name the connection e g the company name or a date however without dots Select a symbol any symbol Confirm with OK Define the interface com1 or com2 at the PC Confirm with OK 8 Appendix 8 3 Transmissi...

Page 76: ...92 12 3321A Issue 19 09 08 Define the connection settings Transmission rate Bits per second CDM units 19200 IT 1000 units 115200 Confirm with OK 8 Appendix 8 3 Transmission of Recognized Data With Mi...

Page 77: ...CDM 3201 Order No BA 92 12 3321A Issue 19 09 08 77 Do not forget to save data 8 Appendix 8 3 Transmission of Recognized Data With Microsoft Hyper Terminal...

Page 78: ...78 CDM 3201 Order No BA 92 12 3321A Issue 19 09 08 Give a file name Confirm with start 8 Appendix 8 3 Transmission of Recognized Data With Microsoft Hyper Terminal...

Page 79: ...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 80: ...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 81: ...ud welding method for metals Survey DVS0902 Arc stud welding DVS0903 Capacitor discharge welding with tip ignition DVS0904 Tips Arc stud welding DVS2927 Resistor projection welding and Arc welding of...

Page 82: ...equirements Personalsafetyandaccidentprevention DIN EN ISO 20345 Personalprotectiveequipment Safetyfootwear DINEN12477 Protectiveglovesforwelders DIN EN 166 Personal eye protection Specifications DIN...

Page 83: ...p0 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 mi...

Page 84: ...roperationsarecarriedoutbyunauthorized persons Warning Unauthorized interference with the stud welding unit as well as unauthorized alteration of the stud welding unit are prohibited and result in com...

Page 85: ...________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ _______...

Page 86: ..._____________ 85221 Dachau Germany __________________________ Postfach 13 46 __________________________ 85203 Dachau Germany __________________________ Productdescription __________________________ Se...

Page 87: ...CDM 3201 Order No BA 92 12 3321A Issue 19 09 08 87 Service Support Service Support...

Page 88: ...ection 20 compressed air supply 20 confirmation 85 confirmation operator sign 9 connecting the welding gun 18 contact 22 31 45 contact welding 26 control cable connector 18 control sleeve 44 controls...

Page 89: ...ons and corrective actions 50 markings 14 material combinations 29 83 material of the welding element 28 material of the workpiece 28 material separation environmentally correct 54 materials rapidly o...

Page 90: ...80 stud welding functional principle 26 stud welding procedure 23 stud welding process 10 stud welding unit 80 support 87 surface of welding element 47 surface workpiece 47 switch electronic 21 switc...

Page 91: ...Order No BA 92 12 3321A Issue 19 09 08 91 welding preparation 28 welding procedure 42 welding process 10 welding spatters 42 welding thyristor 21 welds high strength 28 work piece 80 working place cha...

Page 92: ...92 CDM 3201 Order No BA 92 12 3321A Issue 19 09 08...

Page 93: ......

Page 94: ...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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