HBS ACCU-TWIN 92-10-2280 User manual

©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
Operating Manual
ACCU-TWIN
Power Unit
92-10-2280
2013

2
After-sales service for Germany:
HBS Bolzenschweiss-Systeme GmbH & Co. KG
Felix-Wankel-Strasse 18
85221 Dachau
GERMANY
Phone [phone]
Fax [phone]
E-mail [email protected]
Web www.hbs-info.com
ACCU-TWIN Operating Manual Issue 2013-09 Order No. E-BA 92-10-2280
Translation of the Original Operating Manual
Transmission and duplication of this document, dissemination and notication
of the contents are not permitted unless expressly approved.
All rights, errors and technical amendments reserved.
© HBS Bolzenschweiss-Systeme GmbH & Co. KG

3
©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
Dear Customer,
Many thanks for buying a stud welding unit from HBS Bolzenschweiss-Systeme.
We from HBS wish you every success at all times when working with this stud wel-
ding unit.
The high level of quality of our products is guaranteed by the ongoing further deve-
lopment in the design, equipment and accessories. This may result in differences
between the present operating manual and 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 you discover any errors or unclear points when reading this operating manu-
al, please do not hesitate to contact us.
We would also be grateful for any feedback from you should you have any suggesti-
ons or complaints to make about our product.
HBS Bolzenschweiss-Systeme GmbH & Co. KG
Felix-Wankel-Strasse 18
85221 Dachau
GERMANY

©HBS Bolzenschweiss-Systeme GmbH & Co. KG
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4
Table of Contents
Table of Contents
1 Important Safety Precautions ................................................................... 6
2 Symbols and Terms Used ......................................................................... 9
3 Scope of Supply ....................................................................................... 12
4 Accessories .............................................................................................. 13
5 Technical Data .......................................................................................... 14
6 Intended Use ............................................................................................ 15
7 Warranty ................................................................................................... 16
8 Components of the Power Unit .............................................................. 17
8.1 Main Assemblies ................................................................................................... 17
8.2 Keyboard and Display .......................................................................................... 19
8.3 LED Display .......................................................................................................... 20
8.4 Light emitting diodes (LED) on the external power supply unit ............................ 20
9 Welding Process ...................................................................................... 21
9.1 Contact Stud Welding ........................................................................................... 21
10 Preparing Place of Work and Welding Process .................................... 23
10.1 Preparing Surfaces ............................................................................................... 24
10.2 Adjusting and Inspecting the Welding Gun ........................................................... 25
11 Connection ............................................................................................... 26
12 Welding ..................................................................................................... 27
12.1 Switching on the Power Unit ................................................................................. 27
12.2 Performing the Welding Process .......................................................................... 28
12.3 Additional Information ACCU-TWIN ..................................................................... 32

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Table of Contents
13 Checking the Quality of the Weld ........................................................... 34
13.1 Carrying out Visual Inspection .............................................................................. 34
13.2 Carrying out Bending Test .................................................................................... 35
13.3 Blowing Effect and Remedies ............................................................................... 37
14 Troubleshooting ....................................................................................... 38
15 Shutting Down ......................................................................................... 39
16 Maintenance and Care ............................................................................. 40
16.1 Cleaning ............................................................................................................... 40
Maintenance of Accumulators ............................................................................................ 40
Maintenance Instructions for Chucks ................................................................................. 41
16.2 Inspection and Tests ............................................................................................. 42
16.3 Replacing the Accumulator ................................................................................... 43
17 Storage ..................................................................................................... 44
18 Disposal .................................................................................................... 44
EC Declaration of Conformity ............................................................................. 45
Service & Support ................................................................................................ 46
Index ...................................................................................................................... 47

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6
1 Important Safety Precautions
1 Important Safety Precautions
The target group for this manual are qualied personnel who in view of their tech-
nical training, know-how and experience and their knowledge of the applicable
regulations are able to assess the work assigned to them and to recognise potential
hazards.
Danger from incorrect use
Use the stud welding unit only for the purpose described in this manual.
Otherwise you may endanger yourself or damage the stud welding unit.
You endanger yourself and others if you operate the stud welding unit incor-
rectly 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 unit only when
– You are appropriately trained, instructed and authorised to do so, and
– You have read and completely understood this operating manual.
Never work with the stud welding unit when you are under the inuence of
– Alcohol,
– Drugs or
– Medication.
Danger from unauthorised modications
Never modify the stud welding unit or parts thereof without obtaining a
clearance certicate from the manufacturer.
You will otherwise endanger yourself. This can lead to serious injury or
extensive material damage.

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1 Important Safety Precautions
Danger for wearers of heart pacemakers
Never operate the stud welding unit if you have a heart pace-
maker.
In this case, never remain in the vicinity of the stud welding unit
during welding.
Never operate the stud welding unit if persons with heart pace-
makers are in the vicinity.
Strong electromagnetic elds are produced in the vicinity of the stud
welding unit during welding. These elds may impair the function of
the heart pacemakers.
Danger from fumes and airborne particulates
Switch on the welding fume extractor at the place of work.
Ensure that the room is well ventilated.
Never weld in rooms with a ceiling height of less than 2 m.
Observe furthermore your working instructions and the accident
prevention regulations.
This will help to avoid health damage due to fumes and airborne
particulates.
Danger from glowing metal spatter (re hazard)
Glowing hot weld spatter and liquid splashes, ashes of light and a
loud bang > 90 dB (A) must be anticipated during stud welding.
Inform colleagues working in the immediate vicinity accordingly
before starting work.
Ensure that an approved re extinguisher is available at the place
of work.

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1 Important Safety Precautions
Do not weld when wearing working clothes soiled with inammable
substances such as oil, grease, petroleum, etc.
Wear your proper protective equipment, such as:
– Protective gloves in accordance with the relevant standard,
– Protective goggles with a visor of protection class 2 in
accordance with the relevant standard,
– Non-ammable clothing,
– Full-ear hearing protectors in accordance with the relevant
standard,
– A protective apron over your clothing,
– A helmet when welding above your head,
– Safety shoes.
Remove all inammable materials and liquids from the vicinity of
the place of work before starting welding.
Weld at a safe distance from inammable materials or liquids.
Select a safety distance large enough to ensure that no danger
can arise from weld spatter.
Protection of the stud welding unit
Protect the stud welding unit against the ingress of foreign matter
and liquids caused by cutting or grinding work in the vicinity of your
place of work.
This will help to prolong the service life of your stud welding unit.

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2 Symbols and Terms Used
2 Symbols and Terms Used
The symbols used in this operating manual have the following meaning:
Danger
Warns you of hazards that can lead to injury of persons or to
considerable material damage.
Caution
Problems in the operating procedure can occur if this information is not
observed.
Forbidden for persons with heart pacemaker
Danger
Warns you of electrical hazards
Danger
Warns you of electromagnetic elds that can be generated during welding
These symbols prompt you to wear your personal protective equipment
when working with the stud welding unit.
This symbol prompts you to wear ear protectors. A loud bang > 90 dB (A)
can occur during the welding process.

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10
2 Symbols and Terms Used
Tip
Cross-reference to useful information on the use of the stud welding unit
Cross-references in this operating manual are marked with this
symbol or are printed in italics
Fire hazard
Have a re extinguisher suitable for the working area ready before starting
work.
Work instruction
– List

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2 Symbols and Terms Used
Glossary
Automatic welding head: Device for welding of welding elements
Capacitor: Component for storage of electrical energy.
Light arc: Independent gas discharge between two electro-
des when the current is high enough. A whitish light
is emitted in the process. The light arc allows very
high temperatures to be generated.
Power unit: Device for provision of the electrical energy for
stud welding
Rectier: Electrical component that converts alternating vol-
tage into direct voltage
Stud feeder: Device for automatic feeding of welding elements
Stud welding unit: Power unit including welding gun
Thyristor: Electronic component for contact-free switching of
high currents; switching takes place via the control
input
Welding element: Component such as stud or pin that is welded to
the workpiece
Welding gun: Device for welding of welding elements
Welding parameters: Mechanical and electrical settings at the welding
gun and at the power unit (e.g. spring force, char-
ging voltage)
Workpiece: Components such as sheet metal or tubes to which
the welding elements are to be fastened

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12
3 Scope of Supply
3 Scope of Supply
The basic conguration of your power unit contains the following parts:
No. of
pieces
Part Type Order No.
1 Power unit ACCU-TWIN 92-10-2280
1 External power supply
unit
88-21-490
1 Shoulder strap ACCU-TWIN 88-20-911
1 Socket wrench AF 13 80-41-032
1 Operating manual ACCU-TWIN E-BA 92-10-2280
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).

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4 Accessories
4 Accessories
For example:
Part Order No.
Clamping nut 80-05-454
Chuck 82-55-003
Spark-protection 80-08-124A
Accumulator 80-50-1104
Additional accessories can be found in our extensive accessories catalogue.

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5 Technical Data
5 Technical Data
Power unit ACCU-TWIN – Battery Powered Stud Welding Unit
with twin stud welding gun for CD stud welding
according to current standards
Welding range 2 x M3
Welding material Mild steel, stainless steel
(Aluminium only available to a limited extent)
Welding rate 2 twin welds per minute
Capacitance 80,000 µF
Energy 325 Ws
Charging voltage Max. 90 V
Power source Capacitor
Capacitor charging time Approx. 30 sec
Battery 12 V, 5 Ah (discharge-proof)
Battery capacity 200 twin M3 welds
Battery charging time Max. 10 hours.
Battery life Min. 200 charging cycles;
(no warranty on batteries)
External power supply unit Connection: 100 - 240 V AC, 50 Hz, 0.6 A
Stud spacing Stepless adjustable from 25 mm up to 61 mm
(from 19 mm upon request)
Connection lead 1.5 m
Dimension L x W x H 360 x 135 x 210 mm (without handle)
Dimension welding gun L x W x H 165 x 25 x 95 mm
Weight 7 kg (incl. welding gun)
Weight welding gun 550 g

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6 Intended Use
6 Intended Use
Our stud welding unit are designed and built exclusively for industrial use. Nonindus-
trial use is expressly forbidden due to the lack of know-how about the welding tech-
nology employed and the applicable standards.
The power unit is intended exclusively for stud welding of standardised welding
elements. Any other use will result in the desired strength of the welded joint being
reduced.
The intended use also implies compliance with the intervals and conditions for ins-
pection and maintenance of the power unit and the gun employed.
The stud welding unit must be suitable for welding the welding elements in use.
Welding elements manufactured with the cold formed process have a ange and an
ignition tip. During welding, the ange prevents the arc getting to the cylindric part of
the welding element and increases simultaneously the welding area.

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7 Warranty
7 Warranty
Please refer to the latest "General Terms and Conditions" for the scope of the
warranty.
The warranty does not cover faults caused by e.g.
– Normal wear,
– Improper handling,
– Failure to observe the operating manual,
– Failure to observe the safety precautions,
– Use for other than the intended purpose, or
– Transport damage.
The warranty claim will be voided if modications, changes or service and repair
work is carried out by unauthorised persons. We expressly point out that only
spare parts and accessories or components approved by us may be used. The
same applies analogously to installed units from our sub-suppliers.

17
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8 Components of the Power Unit
8 Components of the Power Unit
8.1 Main Assemblies
1- Charging unit A - Welding circuit
2 - Control
3 - Welding capacitors
4 - Welding thyristor
Via the charging unit (1) the welding capacitors (3) are loaded to the set voltage.
The capacitors store the energy which is required for the welding process.
The electronic switch (4) releases the charging voltage in the right time.
The charging process as well as the welding process are controlled by the control
unit (2).
The positive pole of the capacitoris is connected via the thyristor with one side of the
welding gun. The negative pole is connected to the other side of the welding gun.
The type plate is located on the backside of the power unit.

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8 Components of the Power Unit
Type plate
The type plate contains the following information:
– Manufacturer
– Type
– Order No./Serial No.
– Primary voltage
– Fuse
– Power consumption
– Cooling class
– IP code
– Date

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8 Components of the Power Unit
8.2 Keyboard and Display
1 - Display
2 - Stud counter
3 - Reset stud counter
4 - Stand-by display
green - READY
red - CHARGING
5 - Status indication
red - FAULT
yellow - CONTACT
The status of the stud welding unit is monitored after activation. The current version
number of the software is displayed. The following variables are then captured:
– battery status,
– thyristor defect,
– charging time of capacitors.
After the self-test the number of welds that are still possible will be shown in the
Display (1).
The power unit is equipped with a stud counter. On actuation of the key „Stud coun-
ter“ (2) the number of welded studs appears in the Display (1).
By simultaneously pressing the two keys „Stud counter“ (2) and „Reset stud coun-
ter“ (3) the stud counter is reset to zero.

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8 Components of the Power Unit
8.3 LED Display
Green The power unit is ready for welding.
Red ashing The capacitor battery is charged.
Red The power unit is locked
– if battery is defective
– if thyristor is defective
– in the case of a charging malfunction (exceeding the
charging period)
Yellow if there is electrical contact between both chucks
8.4 Light emitting diodes (LED) on the external power supply unit
1
2
3
1 - LED LADEN (Charge)
2 - LED POL (polarity indicator)
3 - Switch
Switch position to 12 V!
LED "LADEN" lights up green =Normal charge
LED "LADEN" is off =Fully charged accumulator
LED "POL" lights up red =Connection has false polarity
All LEDs off =No charge