HBS 93-20-290C Operating Manual Download

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©HBS Bolzenschweiss-Systeme GmbH & Co. KG

Operating Manual

A 22

Stud Welding Gun

93-20-290C

2021

Summary of Contents for 93-20-290C

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 A 22 Stud Welding Gun 93 20 290C 2021 ...

Page 2: ...s info com A 22 Operating Manual Issue 2021 01 Order No E BA 93 20 290C Translation of the Original Operating Manual Please keep the manual in a safe place for future reference Transmission and duplication of this document dissemination and notification of the contents are not permitted unless expressly approved All rights errors and technical amendments reserved HBS Bolzenschweiss Systeme GmbH Co...

Page 3: ...d your 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 effort to ensure that the information contained in this manual was correct and up to date at the time of delivery We can nevertheless give no guarantee for an absolutely error free document Should ...

Page 4: ...5 Technical Data 14 6 Intended Use 17 7 Warranty 18 8 Design and Function 19 9 Welding Process 20 10 Preparing the Stud Welding Gun 21 10 1 Mounting the Chuck 23 10 2 Mounting the Leg Assembly 24 10 3 Setting the Welding Parameters 26 Adjusting Lift 28 Setting the Insertion Depth Protrusion 29 Adjusting the Hydraulic Damping 30 11 Welding 32 12 Troubleshooting 33 13 Maintenance and Care 35 13 1 Cl...

Page 5: ...Co KG All rights reserved Reprinting in whole or in part only with the approval of the manufacturer Table of Contents 14 Storage 38 15 Disposal 38 Declaration of Incorporation of partly completed Machinery 39 Service Support 40 Index 41 ...

Page 6: ...lding machine You endanger yourself and others if you operate the stud welding machine incorrectly or fail to observe the safety precautions and warnings This can lead to serious injury or extensive material damage Danger for unauthorised operating personnel Work with the stud welding machine only when You are appropriately trained instructed and authorised to do so and You have read and completel...

Page 7: ... within the meaning of the EMF directive In this case never remain in the vicinity of the stud welding machine during welding Never operate the stud welding machine if persons are located nearby who are among the group of workers at particular risk within the meaning of the EMF directive Strong electromagnetic fields are produced in the vicinity of the stud welding machine during welding These fie...

Page 8: ...nce with the relevant standard Non flammable clothing A protective apron over your clothing Full ear hearing protection in accordance with the relevant stan dard A safety helmet when welding above your head Safety shoes Safety goggles with sight glass of protection level 2 in compli ance with the applicable standards and do not look directly into the electric arc Remove all flammable materials and...

Page 9: ...workers Strong electromagnetic fields are produced in the vicinity of the stud welding machine during welding To reduce the danger posed by electromagnetic fields we recommend among other things the following rules of conduct Lay all cables as close together as possible For proper bundling and safeguarding of the cables HBS offers protective tubes in various sizes Do not position yourself between ...

Page 10: ...l damage Caution Problems in operating may occur if this information is not observed No access for people with active implanted cardiac devices No access for persons with implants made of metal No access for pregnant women Danger Warns you of electrical hazards Danger Warns you of electromagnetic fields that can be generated during welding These symbols prompt you to wear personal protective cloth...

Page 11: ...ufacturer 2 Symbols and Terms Used Tip Cross reference to useful information on the use of the stud welding machine Cross references in this operating manual are marked with this symbol or are printed in italics Fire hazard Have a suitable fire extinguisher for the working area ready before starting work Work instruction List ...

Page 12: ...into direct voltage Stud feeder Device for automatic feeding of welding elements Stud welding gun Device for welding of welding elements Stud welding system Stud welding unit including stud welding gun or welding head Stud welding unit Device for provision of the electrical energy for stud welding Thyristor Electronic component for contact free switching of high currents switching takes place via ...

Page 13: ...o 1 Welding gun cable length 4 85 m A 22 93 20 290C 1 Operating manual A 22 E BA 93 20 290C Inspect the shipment for visible damage and completeness immediately on receipt Report any transport damage or missing components immediately to the delivering shipping agent or the dealer address see page 2 4 Accessories For example Mounting tool set 93 40 116 Protective hose complete with zipper 80 11 430...

Page 14: ... depending on leg assembly Stud material Mild steel stainless steel Stud type Any type or shape special chucks if required Length compensation 9 mm automatic Lift Adjustment range 6 mm 0 25 mm steps arresting Damping Adjustable oildamper Welding cable 4 8 m 95 mm IP Code IP 20 protect against humidity Workplace noise level Up to 90 dB A may occur during welding Ambient temperature limits 0 C to 40...

Page 15: ...sembly not included in delivery for stud welding with ceramic ferrule according to current standards Ceramic leg assembly PSC 2 Order no 93 40 040 d Welding range Welding elements RD MD DD PD UD ID dia 16 to 20 mm Shear connectors SD up to dia 13 mm Stud length up to 150 mm Dimension tripod legs 10 x 240 mm Dimension food piece Inner diameter d 28 mm Weight 0 388 kg ...

Page 16: ... d Welding range Shear connectors SD dia 16 mm 5 8 3 4 7 8 Stud length up to 150 mm Dimension tripod legs 10 x 240 mm Dimension food piece Inner diameter d 29 mm Weight 0 380 kg Ceramic leg assembly PSC 2 Order no 93 40 074 d Welding range Shear connectors SD dia 16 mm 5 8 3 4 7 8 Stud length up to 300 mm Dimension tripod legs 10 x 390 mm Dimension food piece Inner diameter d 29 mm Weight 0 551 kg...

Page 17: ... with standardised stud welding elements The use of any other elements will result in the desired strength of the welded joint being diminished The stud welding gun must only be connected to HBS stud welding units Always check with the operating manual of your stud welding unit whether this stud welding gun may be used Observation of the operating manual of the stud welding unit being used is also...

Page 18: ...safety precautions Use for other than the intended purpose or Transport damage Warranty entitlement shall no longer be valid if modifications changes or service and repair work is carried out by unauthorised persons or without the knowledge of the manufacturer Invalidation of warranty entitlement shall also render the declara tion of conformity invalid The CE marking shall be declared invalid by t...

Page 19: ... the chuck where the welding ele ments of the welding gun are manually fed A leg assembly with foot piece where the ceramic ferrule grip is inserted is used to position the welding gun vertically The springy welding elements are projecting out of the ceramic ferrule grip with ceramic ferrule In this way they can be positioned above the aluminum ball or the cone At the front of the welding gun hand...

Page 20: ...n whole or in part only with the approval of the manufacturer 20 9 Welding Process 9 Welding Process This stud welding gun may only be used for drawn arc stud welding Please refer to the original operating manual of the connected stud welding unit for the welding procedure ...

Page 21: ...ot connect the stud welding gun to the stud welding unit until it has been prepared In this way you can avoid any unintentional starting of the welding process Select a leg assembly suitable for your welding element d Ceramic leg assembly PSC 2 Order no 93 40 040 d 28 mm for welding elements RD MD DD PD UD ID dia 16 to 20 mm up to length 150 mm d Ceramic leg assembly PSC 2 Order no 93 40 041 d 29 ...

Page 22: ... 80 30 116 93 40 040 M20 83 50 020 15 80 31 262 93 40 040 Virtually fully threaded studs MD DD Stud dimension Ø d1 Chuck Depth for stud in mm Ceramic ferrule grip Suitable leg assembly M16 83 50 016 15 80 31 262 93 40 040 Partially threaded studs PD Stud dimension Ø d1 Chuck Depth for stud in mm Ceramic ferrule grip Suitable leg assembly M16 83 50 016 15 80 30 116 93 40 040 M20 83 50 020 15 80 31 ...

Page 23: ...rip Suitable leg assembly 16 M10 83 50 016 15 80 31 262 93 40 040 Shear connectors SD Stud dimension Spitzenform A Ø d1 Ø d5 Chuck Depth for stud in mm Ceramic ferrule grip Suitable leg assembly 16 32 83 53 019 12 80 30 219 93 40 041 93 40 074 19 32 83 53 019 12 80 30 219 22 35 83 53 022 12 80 30 222 10 1 Mounting the Chuck Screw the chuck on the thread socket of the welding gun Tighten the chuck ...

Page 24: ...w Loosen the wing screw 1 1 2 2 Tripod leg Now attach the leg assembly to the stud welding gun Clamp the tripod legs 2 with the wing screw 1 Put the welding element up to the stop into the chuck Attention The welding element must firmly sit in the chuck otherwise welding element and chuck would burn Place the ceramic ferrule grip into the foot piece Clamp the ceramic ferrule grip with an allen key...

Page 25: ... with the approval of the manufacturer 10 Preparing the Stud Welding Gun Put on the ceramic ferrule Adjust the foot piece until the stud can be moved in the ceramic ferrule without friction centered Tighten the foot piece with an allen key 4 mm accesso ry Clamp the tripod legs with the wing screw ...

Page 26: ...0 IT 2002 metric 4 imperial US Stud diameter in mm eff diameter in mm Stud diameter in inches approx eff dimeter in inches approx Welding gun parameters A 22 1 Insertion depth P in mm Lift L in mm Hydraulic damping Material of workpiece Mild steel suitable for welding alloyed steel suitable for welding 3 Ø d1 Ø d2 Ø d1 Ø d2 RD 2 M16 13 2 5 8 0 520 3 0 2 0 2 RD 2 M20 16 5 3 4 0 650 3 5 2 2 2 Ø d1 Ø...

Page 27: ...hes approx Welding gun parameters A 22 1 Insertion depth P in mm Lift L in mm Hydraulic damping Werkstoff Werkstück Stahl schweißgeeignet unlegiert legiert 3 shape of tip A Ø d1 Ø d1 SD 2 16 0 5 8 3 5 3 0 2 SD 2 19 0 3 4 4 0 3 75 2 SD 2 22 0 7 8 4 5 4 5 2 1 to be checked by test weldings 3 When welding on galvanized workpieces we recommend increasing the lift 4 according to EN ISO 13918 The maximu...

Page 28: ...w 5 Allen key size 8 Screw off the cap 1 at the rear Use the allen key to turn the adjustment piece for lift counter clockwise to the se lected lift see table under point 10 3 The lift can be adjusted in steps of 0 25 mm The empty space between 0 and 0 25 mm serves to mechanically balance out the lifting ring construction Screw on the cap again You can reduce the lift by turning the adjustment pie...

Page 29: ...overlap size which would be achieved by welding element and base material with seated welding gun before welding This overlap provides the melt for forming the weld collar E E E Insertion depth for welding elements with conical face E Insertion depth for welding elements with plane face Loosen the wing screw at the welding gun and adjust the insertion depth see table under point 10 3 Insertion dep...

Page 30: ...w B to the required number using an allen key size 2 Meaning 0 2 low damping high insertion speed 3 5 medium damping and 6 8 high damping low insertion speed Normally a damping above 2 should not be selected A proper hydraulic damping must be determined via trials The weld pool should not splash off during plunging on the other hand it should form a complete collar around the stud You should consi...

Page 31: ...urrent welding time with lift and pro trusion Example Diameter of the wel ding element Welding current Welding time dia 16 mm 1300 A 0 65 s with ceramic ferrule Optimum parameters for an application may differ from indicated data due to plate thickness welding position coatings type of ceramics ferrules etc Based on stud diameter at the welding place determine welding current and welding time then...

Page 32: ...ng manual of the HBS stud welding unit Danger if used other than for the intended purpose Use the stud welding gun only for ARC stud welding and only in combina tion with stud welding units from manufacturer HBS Bolzenschweiss Systeme GmbH Co KG Felix Wankel Strasse 18 85221 Dachau GERMANY Always check with the operating manual of your stud welding unit whether this stud welding gun may be used ...

Page 33: ...ained personnel Lamellas of chuck are not pretensioned Check lamellas of chuck Try to bend lamellas if possible otherwise replace chuck Trained personnel Welding gun does not weld Wrong welding parame ters selected Check lift on the stud welding gun Change adjusted para meters Trained personnel Check protrusion inser tion depth on the stud welding gun Change adjusted para meters Trained personnel ...

Page 34: ...tory service or authorised agencies Welding gun does not lift in spite of and Short circuit of magne tic circuit of the welding gun Meassure resistance value at control cable connector 18 Ω to 22 Ω between Pin 1 and Pin 2 Replace control cable connector control cable and solenoid Qualified specialists Solenoid defective Meassure solenoid 18 Ω to 22 Ω Replace solenoid Qualified specialists No displ...

Page 35: ... stud welding unit Prior to this disconnect the stud welding gun from the stud welding unit Danger from insufficiently qualified operating personnel Carry out only the work described here on your stud welding gun Repairs may only be carried out by appropriately qualified personnel Inform your dealer or your maintenance department 13 1 Cleaning Clean the casing of your stud welding gun with a sligh...

Page 36: ...ting the chuck in this manual Before every use inspect the bellows on the front part of the stud welding gun for proper seating and or damage Never work with damaged or incorrectly seated bellows This will contribute to a long service life of your stud welding gun Inform your dealer or maintenance department if you discover any dama ge Before every use check that the type designations and adjustme...

Page 37: ...ud welding unit 1 2 3 4 5 1 Cap 2 Marking 3 Scale wheel 4 Slotted screw 5 Allen key size 8 Screw off the cap at the rear Now screw in the lift up to the stop by turning clockwise Now screw out the lift step by step by turning counter clockwise Push the welding gun trigger and check if lift is triggered Repeat this procedure until a lifting motion at the chuck is visible Lock this position with an ...

Page 38: ...hen not in use Protect the stud welding gun from moisture and metallic contamination Store the stud welding gun only under the following ambient conditions Storage temperature 5 C to 50 C 23 F to 122 F Relative humidity 0 50 at 40 C 104 F 0 90 at 20 C 68 F 15 Disposal Dispose of the stud welding gun only via the manufacturer or a specia list disposal company Never dispose of the stud welding gun i...

Page 39: ... 5 2 1 5 4 1 5 5 1 5 6 1 5 8 1 5 10 1 5 11 1 5 15 1 5 16 1 6 1 1 6 2 1 6 3 1 6 4 1 7 1 1 1 7 2 1 7 3 1 7 4 that special technical documentation was compiled in accordance with Part B of Annex VII of the above mentioned regulation and will be transmitted in response to a reasoned request by the national authorities as follows The above mentioned documents will be transmitted by e mail as a data fil...

Page 40: ...tor Detailed 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 connections tightly fastened Yes No Are there any burn marks on plug or screw connections Yes No Is there any other visual damage e g cracks dents Yes No Have you checked the fuses Yes No De...

Page 41: ...ds for the machine 10 hazards for the operator 10 heart pacemaker 7 10 helmet 8 hydraulic damping 26 hydraulic damping adjusting 30 I insertion depth 26 insertion depth setting 29 intended use 17 32 L lift 26 lift adjusting 28 M maintenance and care 35 mounting the chuck 23 O operating manual 13 P protection cap 19 protective apron 8 protective equipment 8 protective equipment personal 10 protecti...

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Page 44: ...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 international hbs info com www hbs info com ...

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