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CPW 0604  BA CPW 0604 Issue 10.09.13 (From Software-Release 0.0.1.31)

25

Connections power unit (230 V)

Power units with connections different from 230 V must be
installed by the customer and separately be fused!

Such power units (IT / ARC) must be re-equipped with the
module undervoltage release, order no. 8080590!

 

3-phase power units must be connected by the customer and
separately be fused!

3 Starting-up

3.5 Connecting the Power Units to the CNC Production Welder

Summary of Contents for CPW 0604

Page 1: ...CPW 0604 CNC Production Welder Operating Manual 2013...

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

Page 3: ...ice in case of malfunction 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 MAGNETICFIEL...

Page 4: ...nt to order some more copies please provide the order number listed in the foot line Importantreminder Dataandinformationhereinwerecollectedwithgreatestcare Althoughwedidourvery besttocorrectlyupdatea...

Page 5: ...place 19 3 2 Requirements of Operating Personnel 20 3 3 Requirements and Installation Instruction with HBS Base Frame 21 3 4 Connecting the Welding Machine to the Primary Power Supply 22 3 5 Connectin...

Page 6: ...RAPH 101 4 10 Menu PARAMETER CNC 103 4 10 1 Description of Parameters 105 4 10 2 Overview Parameters XAxis 107 4 10 3 Overview Parameters YAxis 109 4 10 4 Overview Parameters ZU1Axis 111 4 11 Menu I O...

Page 7: ...155 9 Switching off the CNC Production Welder 156 9 1 Temporary Switching off 156 9 2 Disposal 156 10 Care and Maintenance 157 10 1 Safety Instructions 157 10 2 Maintenance Recommendations 157 10 3 Re...

Page 8: ...viii CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 Table of Contents Table of Contents Table of Contents Table of Contents Table of Contents...

Page 9: ..._________________ OrderNo __________________________ Serial No __________________________ equippedfor __________________________ Stud length 1 VBZ PBZ Dia ________________ Order No __________________...

Page 10: ...10 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 1 General...

Page 11: ...r 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 12: ...apter 8 Switching off the Power Unit in Chapter 9 CareandMaintenance in Chapter 10 Technical Data and much more in Appendix THREAT TO LIFE and risk of serious health and material damage in case of imp...

Page 13: ...f material damage Ban for persons fitted with a pace maker Warning of dangerous electrical voltage Warning of electromagnetic fields Warning of hot surfaces Warning of hand injury Warning of danger of...

Page 14: ...er is only allowed with HBS components and accessories this clause is also part of use as directed TheCNCProductionWelderisintendedtoweldweldingelementsaccordingtocurrent standards see chapter 5 and a...

Page 15: ...estarting up by visual inspection visible damage The following items are to be observed if the power unit is not to be put into operation immediatelyafterdelivery The CNC Production Welder must be sto...

Page 16: ...Production Welder see section 1 2 and 11 1 Make sure that all markings remain clearly visible Type plate Safety symbols Replace illegible or damaged markings Before opening machine disconnect mains Ob...

Page 17: ...CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 17 Markings 1 General 1 7 Markings...

Page 18: ...nt of your power unit contains the following components No of pieces Part Type OrderNo 1 Weldingmachine CPW0604 Project depending 1 Project directory CPW0604 BA CPW 0604 Operatingmanualanddocumentatio...

Page 19: ...cles 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 to risk...

Page 20: ...l instructions in chapter 1 before you start working Instruct any concerned persons before each operation The stud welding unit must only be operated by qualified personnel Let the stud welding unit o...

Page 21: ...BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 21 3 3 Requirements and Installation Instruction with HBS Base Frame 3 Starting up 3 3 Requirements and Installation Instruction with HBS Bas...

Page 22: ...welder to a power supply with a voltage different from the voltage indicated on the type plate Check the current consumption specified on the type plate with the fuse rating of your primary power supp...

Page 23: ...welding current cable of the stud welding unit into the related plug connection of the power unit s Press in the plug and twist firmly clockwise The connection is not secured against working itself l...

Page 24: ...e connection The welding cables must not be coiled during welding Coiled cables work as a coil and may negatively affect the welding result Before welding lay out the cables lengthwise Fix the cables...

Page 25: ...different from 230 V must be installed by the customer and separately be fused Such power units IT ARC must be re equipped with the module undervoltage release order no 8080590 3 phase power units mus...

Page 26: ...26 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 Other connections 3 Starting up 3 5 Connecting the Power Units to the CNC Production Welder...

Page 27: ...31 27 3 6 Connect Pneumatic Stud Switch es PBW to the Stud Welding Machine PBW distribution and connections for 2 stud lengths PBW distribution and connections for 3 stud lengths 3 Starting up 3 6 Co...

Page 28: ...28 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 3 7 Pneumatic Diagram 3 Starting up 3 7 Pneumatic Diagram...

Page 29: ...ny risk of electrical shock When you move your workplace disconnect the components and the ground cables from the CNC Production Welder Proceed in reversed sequence as described in sections 3 5 and 3...

Page 30: ...structure of the stud welding machine and how to use various adjustment options 4 1 Operating Elements 4 1 1 Touch Panel with Control Using the menu on the touch panel the operator can carry out the f...

Page 31: ...of the earth clamps Push button error confirmation Confirmation of one or more errors after elimination Push button STOP Automatic program can be stopped during run Push button START Restart of a pro...

Page 32: ...e initialized 1 ZU1 axis 2 X or Y axis Yellow marked axes are optional Green marked axes are initialized This is a manual function A collision with possible obstructions must be avoided by the operato...

Page 33: ...of the initalization drive is possible by releasing the push button s at any time Aftersuccessfulinitializationthemenuisautomaticallyquitandthestartmenuiscalled up 4 3 Menu STARTMENU Starting from th...

Page 34: ...ram for execution must be activated by selection in the menu PROGRAM SELECT at first Overviewofdisplays Display of program name of the currently selected program Display of current and previous subseq...

Page 35: ...program instruction M00 programmable stop Stop for automatic run Push button Clamp Manual opening and closing of the earth clamp Push button INIT RESET Error confirmation Confirmation of one or more m...

Page 36: ...ram processing the program can only be stopped by a previous stopping using the STOP push button and can be can celled and quit by the touch key CANCEL Softwarepotentiometer Touch key MAX increases dr...

Page 37: ...locked to avoid any danger The STEP function can be cancelled by a press on the push button STOP and subsequent pressing the touch key CANCEL Touch key Pos XY Using Pos XY you can scroll through the...

Page 38: ...arameter Reweld 2 Using P WELD the graphical Reweld editor is called up The Reweld Editor Stud positions of the current program can be displayed here graphically Example Display after executing with t...

Page 39: ...be changed in the X direction Touch key Y With Y the displayed workpiece size can be changed in the Y direction Touch key AUTO With AUTO program execution is automatically simulated until the end of...

Page 40: ...LED display behind rewelding AUTO indicates that rewelding mode is active Start rewelding close door and start with the START pushbutton If no stud positions are selected for rewelding the program is...

Page 41: ...oftware Release 0 0 1 31 41 Example Display after selecting two stud positions for rewelding Example Display after selecting two stud positions for rewelding and subsequent selection with SEL forprogr...

Page 42: ...ion may have another function in the case of a special application Touch key STOP up Only with set option Parameter Stopper 1 Stopper cylinder retractable zero position stop can be raised manually Thi...

Page 43: ...l for the related welding job program is set The following parameters of the currently called program are used Plunge in Min stud length only display to the right above Delay before welding Delay afte...

Page 44: ...44 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 Coordinate systems 4 Function 4 5 Menu MANUAL CONTACT...

Page 45: ...st be re determined after each change of equipment and or change of program The contact signal must always be calibrated for the shortest stud Subsequent options are selected depending on available ma...

Page 46: ...Z 1 V2 feeding a stud from connected VBZ PBZ 2 V3 feeding a stud from connected VBZ PBZ 3 Selection of option Cx Input of stud length which is fed by selected option Vx The entered stud length must ma...

Page 47: ...of positioning The green light displays the currently active condition Execution of positioning via push buttons confirmation and START Selection of drive direction and axis The green light displays t...

Page 48: ...programming via default coordinates Selection by touch key XY POS This touch key is active if the green light is displayed The green light displays the currently active condition Execution of position...

Page 49: ...by touch key STUD This touch key is active if the green light is displayed The green light display shows the currently active condition Execution of stud feeding via push buttons confirmation and STAR...

Page 50: ...section 4 5 2 to contact with work piece see figure to the right In the case of contact with work piece the condition display Contact signal changes the colour from yellow to green TouchkeyENTER Using...

Page 51: ...ed in advance Note the input of stud length with which you want to weld Insert the original work piece Connect the earth clamp Move to desired position The following options are selected depending on...

Page 52: ...hich is fed from selected option Vx The entered stud length must match the real stud length otherwise defective welds may occur Insert the original work piece Connect the earth clamp Move to desired p...

Page 53: ...he green light is displayed The green light display shows the currently active condition Execution of positioning via push buttons confirmation and START The welding head is moved with push buttons fr...

Page 54: ...nual triggering of a weld Selection via touch key WELD This touch key is active if the green light is displayed The green light display shows the currently active condition Execution of positioning vi...

Page 55: ...ng head back to home position Selection via touch key HEAD up This touch key is active if the green light is displayed The green light display shows the currently active condition Execution of positio...

Page 56: ...eed to maximum 100 of parameter manual speed The left beam indicator displays the currently set speed value of manual speed Touch key MIN decreases drive speed Minimum value which can be set 10 of max...

Page 57: ...parameter is enabled A corresponding hardware and sensor extension is necessary for this function Selection via touch key Stopper This touch key is active if the green light is displayed The green lig...

Page 58: ...chapters 1 and 3 The operator must have read and understood the operating manual General Here functions can manually be set and resetted The change of colour shows whether the selected function is ac...

Page 59: ...ved in working position with a press on the keys Another press resets the function T ouch key and function will only be active if the related option is released in the parameter setting PBW 2 The pneu...

Page 60: ...From Software Release 0 0 1 31 4 7 Menu SETUP CNC In this menu the offsets between axis zero position and work piece zero position are defined Changes without check may negatively affect the machine...

Page 61: ...onprovidestheinputofacorrectivevalue withoutpasswordprotection tothe parameters X offset and Y offset This adjustment option can be used in the case of change of chucks concentricity defect adjustment...

Page 62: ...s PROGRAM EDIT PROGRAM SELECT Touch key PROGRAM EDIT Call up the program editor to edit the current program Touchkey PROGRAMSELECT Selection of a program Edit a program name Copy programs Newprogramcr...

Page 63: ...ation you can select programs create programs copy programs edit programs delete programs All programs are saved and managed on a storage medium with USB connection Program names can be entered via an...

Page 64: ...rograms Selection touch keys to scroll through the program administrati on 10 Scrolling in step width 10 100 Scrolling in step width 100 Green light displays the selected condition Touch key Pg Up Upw...

Page 65: ...ation of a program Touch key NEW Using the touch key NEW the input mode New Program is activated Touch key New Program Using the touch key New program the touch keyboard is activated to enter the new...

Page 66: ...the input mode is cancelled A new program is not created Touch key ENTER Using the touch key ENTER the program is newly created under the entered program name This program does not contain any conten...

Page 67: ...Copy a program Touch key COPY Using the touch key COPY the input mode Copy Program is activated Touch key Copy of Using the touch key Copy of the touch keyboard is activated to enter the new program...

Page 68: ...SC the input mode is cancelled The program is not copied Touch key ENTER Using the touch key ENTER the program is copied under the entered program name In the case that the program name already exists...

Page 69: ...2 Edit a Program Touch key EDIT Using the touch key EDIT the program name of a program can be changed Touch key Edit of Using the touch key Edit of the touch keyboard is activated to enter the new pro...

Page 70: ...C the input mode is cancelled The program is not edited Touch key ENTER Using the touch key ENTER the program name of the selected program is edited In the case that the program name already exists a...

Page 71: ...nput is confirmed with ENTER or quit with ESC Touch key ESC Using the touch key ESC the progress of deletion is cancelled The program is not deleted Touch key ENTER Using the touch key ENTER the selec...

Page 72: ...aking an entry you can search for programs that have already been created figure similar A maximum of 12 characters may be used for a search The search function is not case sensitive Example You searc...

Page 73: ...programs can be restored Restored programs are marked with a tilde at the end of the program name Example ENDLOS O_SCHWEISSEN ATTENTION The restorage function is only active until the machine is switc...

Page 74: ...tory wastebasket Papierkorb Content of the directory wastebasket To restore the programs they must be shifted from the directory Wastebasket to the directory Program After this action the system must...

Page 75: ...PROGRAM EDITOR General The PROGRAM EDITOR consists of two menus The first menu is used to enter so called Header dates The second menu is used to enter the program sequence Menu to enter data assigne...

Page 76: ...achieved Min stud length Thisvaluedefinestheminimumstudlengthwhichcanbeprocessedintheprogram This is the link to the automated Z correction if different stud lengths are used Delay pre weld Shielding...

Page 77: ...ding parameter is enabled Parameter counter shift control 1 With this parameter the shift counter can be controlled in automatic mode Used for programs that produce multiple workpieces in a single pro...

Page 78: ...red border These parameters are out of permissible limits Enter parameters which are between upper and lower limits Yellow marked input boxes with red border For this command the inputs are outside t...

Page 79: ...604 Issue 10 09 13 From Software Release 0 0 1 31 79 Blue marked input boxes These parameters are not yet internally processed but used for documentation of set values 4 Function 4 8 Menus PROGRAM EDI...

Page 80: ...oll in the window of the program editor LINE and LINE Scrolling in step width 10 LINE and LINE Scrolling in step width 1 In the case that required data yellow input boxes are insuffi cient or out of i...

Page 81: ...h key R W READ WRITE Using the touch key R W the write protection of the program is activated deactivated In the case of programs which are marked as write protected the input boxes are marked in whit...

Page 82: ...oftware Release 0 0 1 31 Touch key EXIT Quit the menu PROGRAM EDITOR Command input in program editor The editor touch keys are displayed which are required for each command of line parameterinput 4 Fu...

Page 83: ...input with ENTER or quit with ESC Touch key Option Ux Call up of the option selection window see next sheet Touch key Option Bx Call up of the option selection window see next sheet Touch key Option V...

Page 84: ...are Release 0 0 1 31 Command Input Options and Stud Length Display of the related options is depending on machine configu ration Touch key EXIT Touch key to quit the menu INPUT OPTIONS and INPUT STUDS...

Page 85: ...0 Subprogramlabel G22 Subprogramcall up G53 Adjust zero point OFF G54 Adjust zero point ON G90 Dimension input absolute G91 Dimensioninput relative M98 ProgrammableHoldingtimewithoutfurtherfunction M9...

Page 86: ...86 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 Command overview G79 Command overview G78 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 87: ...CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 87 Command overview G00 Command overview G01 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 88: ...88 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 Command overview G41 Command overview G20 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 89: ...CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 89 Command overview G22 Command overview G54 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 90: ...90 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 Command overview G53 Command overview G90 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 91: ...CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 91 Command overview G91 Command overview M98 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 92: ...92 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 Command overview M99 Command overview M00 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 93: ...CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 93 Command overview M10 Command overview M11 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 94: ...94 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 Command overview M20 Command overview M21 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 95: ...CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 95 Command overview M22 Command overview M23 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 96: ...96 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 Command overview M30 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 97: ...CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 97 Programming example Without programmable Z axis 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 98: ...98 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 Programming example With programmable Z axis 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 99: ...CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 99 Programming example With subprogram and programmable stop 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 100: ...100 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 Programming example With subprogram for Pick Up 4 Function 4 8 Menus PROGRAM EDIT PROGRAM SELECT...

Page 101: ...program can only be accessed from the menu PROGRAM EDIT Touch key P_GRAPH Call up of menu window PROGRAM GRAPH The welding program can visually be checked Note In dependence of machine configuration...

Page 102: ...Y the displayed workpiece size can be changed in the Y direction Touch key AUTO With AUTO program execution is automatically simulated until the end of the program No selection is made for rewelding...

Page 103: ...machine parameters General axes and motor parameters X axis General axes and motor parameters Y axis General axes and motor parameters Z axis Menu for inputs and outputs Menu for actual machine config...

Page 104: ...4 Issue 10 09 13 From Software Release 0 0 1 31 General These menus are password protected Access for editing is depending on different password levels Only yellow marked boxes can be edited 4 Functio...

Page 105: ...on Counter Shift check INT 1 0 Without display shift counter 1 With display shift counter in automatic menu 2 Programmable workpiece counter Number of welding heads INT from 2 1 4 Depending on existin...

Page 106: ...106 CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 4 Function 4 10MenuPARAMETERCNC...

Page 107: ...CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 107 4 10 2 Overview Parameters X Axis General axis parameters X axis Motor parameters X axis 4 Function 4 10MenuPARAMETERCNC...

Page 108: ...Operating mode X 2 Gear ratio between motor and round table Speed manual INT 1 Max speed in operating mode 1 manual Min speed resulting Max 3 Speed Automatic INT 1 Max speed in operating mode Automat...

Page 109: ...CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 109 4 10 3 Overview Parameters Y Axis General axis parameters Y axis Motor parameters Y axis 4 Function 4 10MenuPARAMETERCNC...

Page 110: ...Operating mode X 2 Gear ratio between motor and round table Speed manual INT 1 Max speed in operating mode 1 manual Min speed resulting Max 3 Speed Automatic INT 1 Max speed in operating mode Automat...

Page 111: ...CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 111 4 10 4 Overview Parameters ZU1 Axis General axis parameters ZU1 axis Motor parameters ZU1 axis 4 Function 4 10MenuPARAMETERCNC...

Page 112: ...tor and round table Speed manual INT 1 Max speed in operating mode 1 manual Min speed resulting Max 3 Speed Automatic INT 1 Max speed in operating mode Automatic Settings P_win INT Stoppage window adm...

Page 113: ...have read and understood the operating manual When you quit the menu the outputs are not reset Internal inputs of the control Light display white No input active Light display green Input active Input...

Page 114: ...eased after input of the password Password level From level 1 Level 1 is for tool setters Touch key MENU Touch key for change over to the next menu Touch key MENU Touch key for change over to the prev...

Page 115: ...stance menu is quit and the previous menu is called up 4 12 Menu CONFIGURATION Overview Display of existing machine configuration Informationonsoftware Setting system time PLC time and system date PLC...

Page 116: ...tem time is activated Touch key Hour Using the touch key Hour the hour can be edited via Touch numPad Touch key Min Using the touch key Min the minutes can be edited via Touch numPad Touch key Sec Usi...

Page 117: ...em date is activated Touch key DAY Using the touch key DAY the day can be edited via Touch numPad Touch key MONTH Using the touch key MONTH the month can be edited via Touch numPad Touch key YEAR Usin...

Page 118: ...From Software Release 0 0 1 31 4 13 Menu STANDARD VALUES Here you can find recommended standard values for setting a welding job Note the instruction below Touch key EXIT To quit the menu STANDARD VAL...

Page 119: ...are Release 0 0 1 31 119 Overview standard value parameters If no parameter sets are stored a note will be displayed No data base available The following parameters can be taken from the standard valu...

Page 120: ...ts for welding head of series KAH 412 Only standard components are listed below Special equipment remains unregarded Touch key MENU Touch key to switch to the next menu Touch key EXIT Touch key to qui...

Page 121: ...ding head of series VBZ 3 Only standard components are listed below Special equipment remains unregarded Touch key MENU Touch key to switch to the next menu Touch key MENU Touch key to switch to the p...

Page 122: ...artsclamp Only standard components are listed below Special equipment remains unregarded Touch key MENU Touch key to switch to the next menu Touch key MENU Touch key to switch to the previous menu Tou...

Page 123: ...view Menu for status display of all CAN participants Menu for network settings Menu for machine settings Menu for packed malfunctions Menu for malfunction ring buffer archive Parameters for RS232 inte...

Page 124: ...S The status of the CAN BUS can be read out for all participants Status conditions Participant status 3 error CAN member Participant status 4 Waiting for member with CAN status 3 Participant status 5...

Page 125: ...10 09 13 From Software Release 0 0 1 31 125 Touch key ASSIST To call the assistance menu for CAN STATUS The functions of a menu are explained in short Touch key EXIT To quit the menu CAN STATUS 4 Fun...

Page 126: ...in the network can here be configured like IP address Netmask Gateway IP address Setting for HBS service Machine address must be set to 192 168 100 190 release for service laptop Addresses 192 168 100...

Page 127: ...set to 192 168 100 190 release for service laptop Addresses 192 168 100 191 and 192 168 100 192 In any case after activation of edit mode the machine must be restarted or the control must be rebooted...

Page 128: ...write the manufacturer parameters with a new set of parameters Generally we recommend to save the file Factoryset sys using the FTP server or directly from the USB storage and archieve it Touch key ED...

Page 129: ...rom Software Release 0 0 1 31 129 Touch key UpLoad Restores the delivery condition or the last saved parameter set Touch key DownLoad Saves the actual parameter set Touch key EXIT To quit the menu SYS...

Page 130: ...w initialization of the machine In the case of a minor error you can continue after elimination and confirmation This menu becomes automatically active if more than two malfunctions are simultaneously...

Page 131: ...oint value Maintenance Check parameters Initialize error_X axis 1 Axis could not carry out initialization Cancellation at the end of initialization operation Limit switch defective Initialize error_Y...

Page 132: ...switch Check electrically limit switch program entries Check parameters limits position limit switch Check electrically limit switch program entries Check parameters limits position limit switch Chec...

Page 133: ...Check measuring units program Positioning out of limit_ZU4 1 Parameters out of limit Parameter Limits Check measuring units program Power Removal Motor_X axis 1 Emergency power off of axis is active...

Page 134: ...ected power unit Check parameter adjustments Check function of connected power unit Check parameter adjustments Check function of connected power unit Error Control Process CP_ZU3 2 Set limits were re...

Page 135: ...witched on PU type Power unit not present_ZU2 2 No PU detected during initialization Check connections PU switched on PU type Power unit not present_ZU3 2 No PU detected during initialization Check co...

Page 136: ...data format received Check connections PU switched on PU type Read error measuring module RS232_ZU2 2 Defective data format received Check connections PU switched on PU type Read error measuring modul...

Page 137: ...working Replacement by HBS Service Error Power not ON 2 Power release by key ON is missing Press ON key then confirm error Compressed air supply not OK 1 Compressed air sensor not within 4 6 bar Senso...

Page 138: ...g program could not be saved USB medium Program is hold in Retain of control and is saved again after restart Error Reading act program name 2 File with actual welding program name could not be read A...

Page 139: ...2interfaceofthecontrolsystemaremanagedinthismenu Touch key EDIT Touch key release is only possible after password input Password level from level 2 Level 2 is intended for HBS authorized personnel ser...

Page 140: ...ftware Release 0 0 1 31 4 21 Menu COUNTER This function is used to count machined work pieces Number of starts in automatic run executed welds Number of total welds operatinghours Touch key EXIT To qu...

Page 141: ...tective door is opened by force during a period of active protective door lock To re initialize the safety component please follow the instruc tions in the menu If the machine is switched off in this...

Page 142: ...ash pulse Failure warning output Y1 30 min Error in the output test or voltage at output Y1 although the output is switched off 2 flash pulses Failure warning output Y2 30 min Error in the output test...

Page 143: ...nnel Failure to comply renders the warranty void Special function 0 No special function Special function 1 HBS Special function Retractable zero position stop Special function 2 HBS Special function W...

Page 144: ...c During the actual stud welding process do not touch the welding elements chuck or retaining nut nor any electrically conductive parts in their vicinity These parts are all electrically live Step ont...

Page 145: ...on combustibleclothes 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 a...

Page 146: ...andards see appendix MAGNETIC FIELDS During stud welding strong magnetic fields are present Do not weld in the vicinity of electrical systems and machines which could be affected Warning of hot surfac...

Page 147: ...ior to use For information on this topic see WINDOWS EXPLORER Formatting removable media File system FAT 32 No quick formatting 6 1 Structure of the Drive Directory structure on USB flash drive Conten...

Page 148: ...Act System File with error Logfile Archiv ier File with parameter set for delivery condition Factoryset sys File with spare part data base ErsatzteileKAH txt ErsatzteileSpanner txt ErsatzteileVBZ3 txt...

Page 149: ...ate filename CHK filename PRG file name PLM Example update files made available by HBS CPW0604_0_0_1_25 CHK CPW0604_0_0_1_25 PRG UPDATE_CPW0604_0_0_1_25 PLM These are sample file names Your current up...

Page 150: ...0 0 1 31 Step 02 Remove the USB memory stick from the control system Step 03 Copy files CPW0604_0_0_1_25 CHK CPW0604_0_0_1_25 PRG UPDATE_CPW0604_0_0_1_25 PLM to directory CPW Update on your USB memory...

Page 151: ...e Actuate the mains switch Step 07 Initialise the machine in the accustomed manner See menu item 4 2 Step 08 Start the update During the update do not under any circumstances interrupt the power suppl...

Page 152: ...ep 09 Following automatic installation of the update files the following appears in the display RESTART MACHINE Step 10 Switch off the machine Actuate the mains switch Step 11 Restart the machine foll...

Page 153: ...les access to certain memory areas of the control system via Ethernet An update by means of FTP server is reserved for HBS autho rised personnel no further description is provided here Notice to HBS a...

Page 154: ...ssword input depending on selected function Only yellow marked boxes can be edited 7 1 Defined Password Level Nopassword Password level 1 Service personnel of the customer Password QSc1 Q ualified S e...

Page 155: ...lease 0 0 1 31 155 8 Software You find some information on the current software condition in the menu CONFIGURATION In the case you contact the manufacturer please always indica te Software name Softw...

Page 156: ...hing off Switch off the CNC Production Welder Disconnect the stud welding machine from mains supply Protect the CNC Production Welder against ingress of fluids and foreign bodies 9 2 Disposal If you s...

Page 157: ...nents thefollowing maintenancerecommendationsapply General Clean the working area of the machine at least once per shift Depending on work procedure a shorter interval may apply The working area shoul...

Page 158: ...nge of machine X No compressed air Empty pneumatic filter at the machine X Empty pneumatic filter at VBZ X Lubricate linear guidance with ball screw drive X See following pictures Check wear parts rep...

Page 159: ...04 Issue 10 09 13 From Software Release 0 0 1 31 159 Maintenance recommendation Z axis 2M Maintenance recommendation X axis 2M Maintenance recommendation Y axis 2M 10 Care and Maintenance 10 2Maintena...

Page 160: ...CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 10 3 Replacement of support battery of control system all 12 months 10 Care and Maintenance 10 3 Replacement of support battery of control syste...

Page 161: ...20 m min Clearance height work piece max 120 mm Positioning accuracy 0 2 mm of welded stud Welding capacity 20 studs min Control system High performanceSPCIEC61131 3 Display 9 Touchscreen Keyboard To...

Page 162: ...by the customer and separately be fused Such power units IT ARC must be re equipped with the module undervoltage release order no 8080590 Operating such power units is not permitted without this modu...

Page 163: ...1 31 163 11 2 Environmentally Admissible Disposal After repair of the power unit dispose replaced parts in an environmentally admissible way Used materials Steel Nonferrousmetals brass copper Plastics...

Page 164: ...tic stud feeding of welding elements PBW Pneumatic Stud Switch PBZ Pneumatic Stud Feeder VBZ Automatic Stud Feeder Stud welding unit Power unit inclusive welding gun Thyristor Electronic component con...

Page 165: ...welding method for metals General DVS0902 Drawn arcstudwelding DVS0903 Capacitor discharge stud welding with tip ignition DVS0904 Instructions for practice Arc stud welding DVS2927 Resistor projection...

Page 166: ...fetyandaccidentprevention DIN EN ISO 20345 Personalprotectiveequipment Safetyfootwear DINEN12477 Protectiveglovesforwelders DIN EN 166 Personal eye protection Specifications DIN EN 352 1 Hearing prote...

Page 167: ...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 2 210 N...

Page 168: ...81 0 18 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 current standards 1 weldable All given values are le...

Page 169: ...are carried out by unautho rized persons Warning Unauthorized interference with the stud welding unit as well as unauthorized alteration of the stud welding unit are prohibited and result in complete...

Page 170: ...certain hazardous substances in electrical and electronic equipment 2011 65 EU Following harmonised standards or parts thereof were applied DIN EN 60974 1 Arc welding equipment Part 1 Welding power so...

Page 171: ...__________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ______________...

Page 172: ...________________________ 85221 Dachau Germany __________________________ Postfach 13 46 __________________________ 85203 Dachau Germany __________________________ Productdescription __________________...

Page 173: ...CPW 0604 BA CPW 0604 Issue 10 09 13 From Software Release 0 0 1 31 173 Service Support Service Support...

Page 174: ...ommand M22 85 95 CNC command M23 85 95 CNC command M30 85 96 CNC command M98 85 91 CNC command M99 85 92 command input 82 84 command overview CNC commands 85 company specific maintenance instruction 1...

Page 175: ...LIZE 32 input as absolute dimension 90 inputs CAN OPEN 113 inputs internal 113 installation instruction 21 intended use 14 IP address 126 IT pin with internal thread 167 168 K key switch 31 key switch...

Page 176: ...rly instructed qualified 11 personnel qualified 11 20 place of operation 14 plunge in 76 plunger 59 plunger in active position 85 95 plunger in released position 85 95 pneumatic diagram 28 pneumatic s...

Page 177: ...tatus display CAN 123 STEP 37 38 39 102 stopper 59 stopper in active position 59 85 stopper in released position 59 85 structure of power unit 30 stud feeder 164 stud length 84 stud welding functional...

Page 178: ...1 31 welding parameters determination 51 welding position 53 welding time 79 work piece 164 work piece coordinate system 44 workpiece sensor 143 X X Offset 60 Y Y Offset 60 Z zero point machine X axi...

Page 179: ......

Page 180: ...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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