HBS IT 1002 Manuale utente
IT 1002
Power Unit
Ceramic/Gas Version
93-66-1202
Operating Manual
ii
ii IT 1002 Order No. BA 93-66-1202 Issue 01.06.08
IT 1002 Operating Manual, Issue 06/2008 Order No. BA 93-66-1202
Customer Service in Germany:
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
Web www.hbs-info.com
Copyright:
The information contained herein may not be copied, reproduced, adapted,
merged, translated or used without the prior written consent of the copyright
owner.
Adaptations, errors and technical modifications reserved without prior notice.
© HBS Bolzenschweiss-Systeme GmbH & Co. KG
iii
IT 1002 Order No. BA 93-66-1202 Issue 01.06.08 iii
Dear customer,
Thank you very much for purchasing a power unit from HBS Bolzenschweiss-
Systeme.
We from HBS wish you always successful working with this stud welding unit.
We ask you to observe the following points:
– Store the operating manual in a way that it can always be accessed by the
operator.
– Let the operator sign before starting up that he has read and completely under-
stood the operating manual.
– This operating manual applies only to this stud welding unit.
– Protect the stud welding unit from unauthorized use.
– The stud welding unit must only be operated by trained personnel.
– Let an electrician check whether the wall sockets where you want to connect the
related stud welding unit, are properly fused and grounded.
– Inform our customer service in case of malfunction.
– In case of accident, inform a physician and the responsible official body.
THREAT TO LIFE!
Persons fitted with a pace maker must not operate the stud
welding machine.
MAGNETIC FIELDS!
During stud welding, strong electro-magnetic fields are
generated. Do not weld in the vicinity of the electrical
equipment which could be affected.
Safety instructions are a delicate subject. Anybody who handles a stud welding
unit, whether it is the welding gun or the power unit, should be familiar with them,
because improper use of stud welding units can be dangerous to life.
For your own sake you should know the safety instructions for operating your HBS
stud welding units inside out.
In addition to the protection of your health and the capital value of the enterprise, the
safety instructions are intended to clarify any responsibilities, which arise from
ownership and operation of the equipment.
This chapter of the operating manual offers you clear and easy to understand information
for the safe operation of your HBS stud welding unit.
iv
iv IT 1002 Order No. BA 93-66-1202 Issue 01.06.08
Your power unit may differ in some details from the captions in this manual. This has
no effect on the operation of the welding machine.
Should you have questions about this manual or in case you want to order some more
copies, please provide the order number listed in the foot line.
Important reminder:
Data and information herein were collected with greatest care. Although we did our very
best to correctly update any information up to the time of delivery, there is no guarantee
in respect of errors.
If you should detect errors or mistakes right in this manual, please contact us:
HBS Bolzenschweiss-Systeme GmbH & Co. KG
Felix-Wankel-Strasse 18
85221 Dachau / Germany
A feedback blank is provided in the appendix.
IT 1002 Order-No. BA 93-66-1202 Issue 01.06.08 v
Table of Contents
1 General ............................................................................................. 9
1.1 Guide to this Operating Manual .................................................................. 10
1.2 Safety Symbols .......................................................................................... 11
1.3 General Safety Instructions ........................................................................ 12
1.4 Intended Use .............................................................................................. 12
1.5 Transportation, Packaging, Storage ........................................................... 13
1.6 Accompanying Documents ........................................................................ 13
1.7 Markings ..................................................................................................... 14
2 Delivery ........................................................................................... 15
3 Starting-up ..................................................................................... 16
3.1 Requirements of Workplace ...................................................................... 16
3.2 Connecting the Power Unit to the Primary Power Supply .......................... 17
3.3 Connecting the Welding Gun to the Power Unit ......................................... 18
3.4 Ground Connection .................................................................................... 19
3.5 Shielding Gas Connection .......................................................................... 20
3.6 Change Working Place .............................................................................. 20
4 Function ......................................................................................... 21
4.1 Components of the Power Unit .................................................................. 21
4.1.1 Power Unit ............................................................................................................. 21
4.1.2 Control Unit ............................................................................................................ 22
4.2 Keyboard and Display ................................................................................ 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
5.2.2 Drawn-Arc Stud Welding with Shielding Gas .......................................................... 29
5.2.3 Short-Cycle Drawn-Arc Stud Welding with Shielding Gas ....................................... 30
5.2.4 Drawn-Arc Capacitor-Discharge Stud Welding ........................................................ 30
5.3 Welding Preparation ................................................................................... 31
5.4 High-strength Welds ................................................................................... 31
vi IT 1002 Order-No. BA 93-66-1202 Issue 01.06.08
5.5 Determination of Welding Parameters ....................................................... 31
5.6 Switching on the Power Unit ...................................................................... 33
5.6.1 Adjusting the Welding Time ................................................................................... 35
5.6.2 Adjusting the Welding Current ................................................................................ 35
5.6.3 Adjusting the Gas Pre-Flow Time ........................................................................... 35
5.6.4 Library Mode .......................................................................................................... 36
5.6.5 Electrode Mode ...................................................................................................... 36
5.7 Welding Procedure .................................................................................... 37
5.8 Checking the Quality of the Weld ............................................................... 38
5.8.1 Visual Inspection ................................................................................................... 38
5.8.2 Bending Test .......................................................................................................... 39
5.8.3 Arc Blow Effect ...................................................................................................... 41
5.9 Malfunctions and Corrective Actions .......................................................... 42
5.10 Welding Elements ...................................................................................... 43
6 Switching off the Power Unit ........................................................ 46
6.1 Temporary Switching off ............................................................................. 46
6.2 Disposal ..................................................................................................... 46
7 Care and Maintenance .................................................................. 47
7.1 Safety Instructions ...................................................................................... 47
7.2 Regular Maintenance Operations ............................................................... 47
7.3 Tools to be Used ......................................................................................... 47
7.4 Open the Power Unit .................................................................................. 48
8 Appendix ........................................................................................ 49
8.1 Technical Data ............................................................................................ 49
8.2 Spare Parts ................................................................................................ 50
8.3 Electrical Circuit Diagram .......................................................................... 62
8.4 Environmentally Admissible Disposal ......................................................... 63
IT 1002 Order-No. BA 93-66-1202 Issue 01.06.08 vii
Glossary ......................................................................................... 64
Regulations and Standards .......................................................... 65
Further Instructions ....................................................................... 67
Guarantee Clauses ........................................................................ 68
Confirmation .................................................................................. 69
Feedback ........................................................................................ 70
Service & Support ......................................................................... 71
Index ............................................................................................... 72
viii IT 1002 Order-No. BA 93-66-1202 Issue 01.06.08
IT 1002 Order No. BA 93-66-1202 Issue 01.06.08 9
1 General
Persons addressed by this operating manual
This operating manual is written for operators, personnel of the end user, and
authorized service technicians. It provides you with all necessary information to
operate the power unit.
Required user qualification
The power unit must only be operated by qualied personnel.
Let the power unit only be operated by persons who
– arequaliedthroughasuitabletrainingaccordingtothecurrentstandards(see
appendix),
– are properly instructed,
– are physically and intellectually suitable,
– can be expected to reliably fulll the requested job.
What else must the owner observe?
Make sure that this operating manual is always in reach of the stud welding
unit.
Read the entire manual before operating the power unit.
Strictly observe the safety instructions.
Before starting up the power unit, let the operator sign the conrmation that he/
she has read and fully understood the operating manual (see appendix).
Do not commence stud welding until you have understood all operating
processes.
Contact us if there are any doubts on certain operating procedures.
Protect the power unit against unauthorized use.
Inform our service in case of malfunction.
Basedonthisoperatingmanual,acompanyspecicworkorder,aswellasacompany
specicmaintenanceinstruction must be drawn up. Thecompanyspecicwork order
must consider the special user conditions in your company.
Makesurethatoperatorsofthewelderareprovidedwithandwearpersonalprotective
equipment, e.g. protective goggles, gloves, shoes, ear protection etc.
Owners and operators make sure that the power unit is only used as directed.
During any activity such as transportation, set-up, (re-)assembly, production,
maintenance etc. observe the information given in this operating manual.
10 IT 1002 Order No. BA 93-66-1202 Issue 01.06.08
1.1 Guide to this Operating Manual
This operating manual provides you with the following information
"Delivery" in Chapter 2
"Starting-up" in Chapter 3
"Functional Principle" in Chapter 4
"Stud Welding Process" in Chapter 5
"Switching o the Power Unit" in Chapter 6
"Care and Maintenance" 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 notes in this
operating manual.
Note for qualified operators (see chapter 1).
All instructions contained in this manual must also be observed
by qualified operators.
The welding process and the sequence of procedures to carry
out a weld are described in chapter 5.
Altri manuali per IT 1002
1
Questo manuale è adatto per i seguenti modelli
1
Indice
Altri manuali HBS Generatore portatile
