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A 22 Order No. BA 93-20-290   Issue 01.03.08

v

Table of Contents

1

General ............................................................................................. 7

1.1

Guide to this Operating Manual .................................................................... 8

1.2

Safety Symbols ............................................................................................ 9

1.3

General Safety Instructions ........................................................................ 10

1.4

Intended Use

.............................................................................................. 10

1.5

Transportation, Packaging, Storage ........................................................... 11

1.6

Accompanying Documents ........................................................................ 11

1.7

Markings

..................................................................................................... 12

2

Delivery........................................................................................... 13

3

Starting-up ..................................................................................... 14

3.1

Requirements of Workplace ...................................................................... 14

3.2

Connecting the Welding Gun to the Power Unit ......................................... 15

3.3

Ground Connection .................................................................................... 16

3.4

Change Working Place .............................................................................. 17

4

Function ......................................................................................... 18

4.1

Components of the Welding Gun Ceramic ................................................ 18

4.2

Installation of Chuck and Tripod.................................................................. 19

4.3

Adjustment of Plunging Depth (Projection)................................................. 20

4.4

Adjustment of Lift ........................................................................................ 21

4.5

Adjustment of Lift Scale.............................................................................. 21

4.6

Adjustment of Hydraulic Damping .............................................................. 22

5

Stud Welding Procedure ............................................................... 23

5.1

Safety Instructions ...................................................................................... 23

5.2

Functional Principle of Stud Welding .......................................................... 26

5.2.1

Drawn-Arc Stud Welding with Ceramic Ferrule

....................................................... 28

5.3

Welding Preparation ................................................................................... 29

5.4

High-Strength Welds .................................................................................. 29

5.5

Determination of Welding Parameters ....................................................... 30

Содержание 93-20-290

Страница 1: ...A 22 Welding Gun 93 20 290 Operating Manual...

Страница 2: ...e 18 85221 Dachau Germany Phone 49 0 8131 511 0 Fax 49 0 8131 511 100 E mail po hbs info com Web www hbs info com Copyright The information contained herein may not be copied reproduced adapted merged...

Страница 3: ...malfunction In case of accident inform a physician and the responsible o cial body THREATTOLIFE Persons tted with a pace maker mu not operate the ud welding machine MAGNETICFIELDS During ud welding r...

Страница 4: ...re copies please provide the order number li ed in the foot line Importantreminder Dataandinformationhereinwerecollectedwithgreate care Althoughwedidourvery be tocorrectlyupdateanyinformationuptotheti...

Страница 5: ...un to the Power Unit 15 3 3 Ground Connection 16 3 4 Change Working Place 17 4 Function 18 4 1 Components of the Welding Gun Ceramic 18 4 2 Installation of Chuck and Tripod 19 4 3 Adju ment of Plungin...

Страница 6: ...witching o the Welding Gun 40 6 1 Temporary Switching off 40 6 2 Disposal 40 7 Care and Maintenance 41 7 1 Safety In ructions 41 7 2 Regular Maintenance Operations 42 8 Appendix 43 8 1 Technical Data...

Страница 7: ...he safety in ructions Before arting up the welding gun let the operator sign the con rmation that he she has read and fully under ood the operating manual see appendix Do not commence ud welding until...

Страница 8: ...he Welding Gun in Chapter 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 weldin...

Страница 9: ...al mean Threat to life or risk of personal injury Risk of material damage Ban for persons tted with a pace maker Warning of dangerous electrical voltage Warning of electromagnetic elds Wear protective...

Страница 10: ...weld welding elements according to actual andards 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 welding gun...

Страница 11: ...can only be checked before arting up by visual inspection visibledamage The following items are to be observed if the welding gun is not to be put into operation immediatelyafterdelivery The welding g...

Страница 12: ...isible Type plate The type plate contains the following data Manufacturer Type OrderNo SerialNo Primaryvoltage Fuse Powerconsumption Cooling class Protection class Date Safety symbols Replace illegibl...

Страница 13: ...290 Issue 01 03 08 13 2 Delivery The basic equipment of your welding gun contains the following components No of pieces Part Type OrderNo 1 Welding gun cable length 4 85 m A 22 93 20 290 1 OperatingM...

Страница 14: ...regulations of the o cial bodies see appendix Weld only in adequate di ance from combu ible articles or liquids Before you art welding remove any combu ible articles or liquids in vicinity of the work...

Страница 15: ...it and mu not ay in its vicinity during welding During the actual welding process you mu expect red hot welding spatters possibly liquid spatters a ash and a loud bang 90 dB A Alert any colleagues who...

Страница 16: ...lding gun cables mu not be coiled during welding Coiled cables work as a coil and may negatively a ect the welding result Before welding lay out the cables lengthwise Fix the cables Strong magnetic el...

Страница 17: ...metrical connection The welding location mu lie directly between the two ground clamps 3 4 Change Working Place Switch o the power unit In this way you avoid any risk of electrical shock When you move...

Страница 18: ...ted Positioned at the front of the welding gun there is the ud chuck where the welding elements of the welding gun are manually fed A tripod with foot piece where the ceramic ferrule holder is inserte...

Страница 19: ...uck and Tripod Welding with Ceramic Ferrule Screw the chuck on the thread art of the welding gun and thighten it rmly with a wrench SW 14 17 accessory Put the ud up to the op into the chuck Attention...

Страница 20: ...Allan key 5 mm accessory Tighten the tripod legs with an Allan screw 4 3 Adju ment of Plunging Depth Projection Theplungingdepthcharacterizestheoverlapsizewhichwouldbeachievedbywelding elementandbasem...

Страница 21: ...tion see section 5 5 4 5 Adju ment of Lift Scale Screw o the cup at the rear Now you can screw in the lift up to the op by turning clockwise Now you can screw out the lift ep by ep by turning counter...

Страница 22: ...set lower than in horizontal position also with larger uds There mu be no friction between ud and ceramic ferrule if so center the foot plate of the welding gun When triggering the welding gun key the...

Страница 23: ...electrical shock and arc During the actual ud welding process do not touch the ud chuck or retaining nut nor any electrically conductive parts in their vicinity These are all electrically life Step on...

Страница 24: ...ds see appendix non combu ibleclothes ear protection to current andards see appendix a protective apron over your clothes a protective headgear when welding overhead Before arting to weld remove all c...

Страница 25: ...ers a ash and a loud bang 90 dB A Alert any colleagues who are occupied in the vicinity of the welder Wear your personal protective equipment according to actual andards see appendix MAGNETIC FIELDS D...

Страница 26: ...e appendix The andards assign this method of joining pin shaped elements with plane workpieces to the so called Arc Pressure Welding code BH Joining is carried out in pla ic or lique ed condition of t...

Страница 27: ...Item Drawn arc stud welding with ceramic ferrule ring Drawn arc stud welding with shielding gas Short cycle stud welding with shielding gas Capacitor discharge stud welding with drawn arc Diameter we...

Страница 28: ...o the weld pool by a formation of metal vapor in the arc chamber abilizes and concentrates the arc thus decreasing the arc blow e ect formsthemeltunderpressuretoa weldcollarandsupportstheweldpoolonave...

Страница 29: ...ck the chuck for proper seat see operating manual of according power unit Before welding make sure that the bellows are checked for damage and proper seat 5 4 High Strength Welds The following mu be r...

Страница 30: ...cessary For an assessment of welding results see sections 5 7 and 5 8 Determination of welding time Data given in the following table are only guidelines They mu be veri ed by trial welds on the actua...

Страница 31: ...ear always your personal protective equipment according to actual andards see appendix Insert the welding element into the chuck As soon as the power unit is ready for the welding process place the we...

Страница 32: ...element w ithin tolerance after w elding Correct parameters None Contraction of w eld collar Plunging depth or lift too low Increase plunging depth check lift and centering of the ceramic ring w eldin...

Страница 33: ...rections The bending te is passed if a crack or a fracture of the welded zone does not occur Please note the in ructions on fault recognition and corrective actions in chapter 5 You don t need to te a...

Страница 34: ...ment above weld collar Correct parameters none Fracture in the weld metal Many pores Welding energy too low Plunging speed too low Unsuitable stud base material combination Increase welding energy Inc...

Страница 35: ...ction of the arc It causes a single sided melting of the ud material increased pore formation and undercuts in the weldingarea The arc blow e ect is proportional to the current and can be in uenced by...

Страница 36: ...gger In case of no flow Replace control cable Qualified personnel Micro sw itch defective w ith present contact signal on pow er unit Check micro sw itch w ith pressed w elding gun trigger for electri...

Страница 37: ...ar care not to mix up di erent lots Slighte variations in geometry of the welding elements especially of the ignition tip require modi ed settings of the welding process Threaded stud RD MR Diameter L...

Страница 38: ...eramic M12 20 50 mm 83 50 012 M16 20 50 mm 83 50 016 Materials S235 St37 3k 4 8 1 4301 1 4303 Head stud SD Diameter Length Chuck ceramic 1 2 13 50 175 mm 83 53 012 5 8 16 50 175 mm 83 53 019 3 4 19 50...

Страница 39: ...4301 1 4303 Ceramic ferrule UF for head stud SD Diameter Chuck ceramic ferrule 1 2 80 30 213 5 8 80 30 219 3 4 80 30 219 7 8 80 30 222 Materials S235 St37 3k 4 8 1 4301 1 4303 Welookforwardtoconsultyo...

Страница 40: ...6 1 Temporary Switching o Switch o the power unit Unplug the control cable and the welding cable from the power unit Protect the ud welding gun again ingress of uids and foreign bodies 6 2 Disposal If...

Страница 41: ...provide long life expectancy 7 1 Safety In ructions Let maintenance and repair operations be carried out only by quali ed personnel or by your competent service technician Before you art any maintena...

Страница 42: ...nect control cable and welding cable from power unit Clean the surface of the welding gun of dirt and du Do not use any solvent containing cleaning agents Solvent containing cleaning agents may damag...

Страница 43: ...0 63 dependingontripod Stud material Mild eel or ainless eel Stud type Any type or shape special chucks if required Lengthadju ment 9 mm 0 35 automatic Stroke Adju ment range 6 mm 0 24 0 25 mm 0 01 ep...

Страница 44: ...5 932 Lengthcompensation complete 13 1 80 05 540 Pressurespringforlengthcompensation 15 1 88 15 939 Cap complete 17 1 88 15 943 Plungingdamper 19 1 88 15 944 Liftdamper 21 1 88 15 941 Stativ support c...

Страница 45: ...A 22 Order No BA 93 20 290 Issue 01 03 08 45 Welding gun type A 22 ceramic 93 20 290...

Страница 46: ...od 10 x 240 complete 93 40 041 for Shear connectors dia 16 to 22 mm Position Quantity OrderNo Description 1 1 80 41 028 Foot piece 5 2 80 40 110 Leg10 240 6 2 80 40 109 Coverplatetripod 11 2 80 10 103...

Страница 47: ...od 10 x 390 complete 93 40 074 for Shear connectors dia 16 to 22 mm Position Quantity OrderNo Description 1 1 80 41 028 Foot piece 5 2 80 40 493 Leg10 390 6 2 80 40 109 Coverplatetripod 11 2 80 10 103...

Страница 48: ...li ceramic tripod 10 x 390 A 22 1 complete 93 40 073 Position Quantity OrderNo Description 1 1 88 15 824 Foot piece 5 2 80 40 493 Leg10 390 6 2 80 40 109 Coverplatetripod 11 2 80 10 1035 Coverplate 12...

Страница 49: ...eveswithinternal thread and pins 12 mm e 13 mm 83 50 012 16 mm e 13 mm 83 50 016 larger on reque Concreteanchorsand head uds 1 2 25 mm e 8 mm 83 53 012 5 8 3 4 32 mm e 12 mm 83 53 019 7 8 35 mm e 12 m...

Страница 50: ...2 A 2 2 A 2 2 A 2 2 A A 22 ceramic Ceramic tripod complete PSC2 Ceramic tripod complete PSC2 Ceramic tripod complete PSC2 Ceramic tripod complete PSC2 Ceramic tripod complete PSC2 Stud 4 12 mm 22 mm...

Страница 51: ...Issue 01 03 08 51 8 4 Environmentally Admissible Disposal After repair of the welding gun dispose the replaced parts in an environmentally admissible way Used materials Steel Non ferrous metals brass...

Страница 52: ...der Device for the automatic ud feeding of welding ele ments Stud welding unit Power unit inclusive welding gun Thyri or Electronic component contactless switch which will let the current only pass th...

Страница 53: ...welding method for metals General DVS0902 Drawn arc udwelding DVS0903 Capacitor discharge ud welding with tip ignition DVS0904 In ructions for practice Arc ud welding DVS2927 Resi or projection weldi...

Страница 54: ...ompatiblity EMC requirements Personalsafetyandaccidentprevention DIN EN ISO 20345 Personalprotectiveequipment Safetyfootwear DINEN12477 Protectiveglovesforwelders DIN EN 166 Personal eye protection Sp...

Страница 55: ...1 2 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 21...

Страница 56: ...lledifrepairoperationsarecarriedoutbyunauthorized persons Warning Unauthorized interference with the ud welding unit as well as unauthorized alteration of the ud welding unit are prohibited and result...

Страница 57: ...approval by HBS Description of equipment Welding Gun Type A 22 Order No 93 20 290 Serial No Applicable EC guidelines and corresponding andards Low voltage guideline 2006 95 EC DIN EN 60974 1 Arc weldi...

Страница 58: ...__________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ _____...

Страница 59: ...______________ 85221 Dachau Germany __________________________ Po fach 13 46 __________________________ 85203 Dachau Germany __________________________ Productdescription __________________________ Se...

Страница 60: ...60 A 22 Order No BA 93 20 290 Issue 01 03 08 Service Support...

Страница 61: ...ns 42 cold formed process 37 company speci c maintenance in ruction 7 company speci c work order 7 components of the welding gun 18 concrete anchors and head uds 49 con rmation 58 con rmation operator...

Страница 62: ...of 7 operation improper 31 operators 7 order number 13 44 46 47 48 ordering spare parts 44 56 P pace maker 9 15 25 packaging 11 personal injury 9 personnel 7 personnel properly in ructed quali ed 7 p...

Страница 63: ...F 55 threaded uds with ange FD 55 threaded uds with reduced shaft RD RF 55 threat to life 8 thyri or 52 torque 30 55 toxic vapors 24 training according to current andards 7 transportation 7 transporta...

Страница 64: ...64 A 22 Order No BA 93 20 290 Issue 01 03 08...

Страница 65: ......

Страница 66: ...HBS Bolzenschweiss Sy eme GmbH Co KG Felix Wankel Strasse 18 85221 Dachau Germany Phone 49 0 8131 511 0 Fax 49 0 8131 511 100 E mail po hbs info com www hbs info com...

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