HBS ARC 1550 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
ARC 1550
Power Unit
93-10-1552A
2012
2
After-sales service for Germany:
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 [email protected]
Web www.hbs-info.com
ARC 1550 Operating Manual Issue 2012-07 Order No. E-BA 93-10-1552A
Translation of the Original Operating Manual
Transmission and duplication of this document, dissemination and notication
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
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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
9 Welding Process ...................................................................................... 21
10 Preparing Place of Work and Welding Process .................................... 27
10.1 Preparing Surfaces ............................................................................................... 28
10.2 Checking the Welding Gun ................................................................................... 29
11 Connection ............................................................................................... 30
11.1 Connecting the Welding Gun to the Power Unit ................................................... 31
11.2 Connecting the Ground Cable .............................................................................. 32
11.3 Shielding Gas Connection .................................................................................... 33
11.4 Connecting the Power Unit to the Mains Supply .................................................. 34
12 Welding ..................................................................................................... 35
12.1 Switch on the Power Unit ..................................................................................... 35
12.2 Determining the Welding Time ............................................................................. 36
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Table of Contents
12.3 Setting the Welding Time ...................................................................................... 41
12.4 Switching on the Energy Control .......................................................................... 41
12.5 Adjusting the Gas Pre-Flow Time ......................................................................... 42
12.6 Performing the Welding Process .......................................................................... 43
13 Checking the Quality of the Weld ........................................................... 47
13.1 Carrying out Visual Inspection .............................................................................. 47
13.2 Carrying out Bending Test .................................................................................... 48
13.3 Optimization of welding parameters ..................................................................... 50
13.4 Blowing Effect and Remedies ............................................................................... 51
14 Troubleshooting ....................................................................................... 52
15 Shutting Down ......................................................................................... 54
16 Maintenance and Care ............................................................................. 55
16.1 Cleaning ............................................................................................................... 55
16.2 Inspection and Tests ............................................................................................. 56
17 Storage ..................................................................................................... 57
18 Disposal .................................................................................................... 57
EC Declaration of Conformity ............................................................................. 58
Service & Support ................................................................................................ 59
Index ...................................................................................................................... 60
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6
1 Important Safety Precautions
1 Important Safety Precautions
The target group for this manual are qualied 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 inuence of
– Alcohol,
– Drugs or
– Medication.
Danger from unauthorised modications
Never modify the stud welding unit or parts thereof without obtaining a
clearance certicate 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 3 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 inammable
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 inammable materials and liquids from the vicinity of
the place of work before starting welding.
Weld at a safe distance from inammable 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 equip-
ment 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 electrodes
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
Rectier: Electrical component that converts alternating volta-
ge 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 conguration of your power unit contains the following parts:
No. of
pieces
Part Type Order No.
1 Power unit ARC 1550 93-10-1552A
1 Operating manual ARC 1550 E-BA 93-10-1552A
During transport and set-up of the machine, safety against tilting is
only guaranteed up to an angle of 45°.
A lift unit with a hook can be used for lifting and transporting the
power unit.
Lifting the power unit using the handle is not permitted.
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
The following ground cables are available as accessories:
No. of
pieces
Part Type Order No.
1 Ground cable 5 m, 50 mm² 93-40-013
(2 pieces required)
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14
5 Technical Data
5 Technical Data
Stud Welding Unit ARC 1550
for ARC stud welding according to current standards
Welding range M3 - M20 RD, Ø 2 - 19 mm
Welding material Mild steel, stainless steel
Welding rate 3 to 35 studs/min (depending on application
and stud dia)
Welding current 1,550 A
Current adjustment range 500 - 1,550 A
(500 A - 800 A - 1,000 A - 1,200 A - 1,550 A)
Welding time 5 - 1.500 msec (stepless)
Primary power 400 V, 3 phases, 50/60 Hz, 63 AT
(alternative input voltages available)
Primary plug 63 A (at 400 V mains)
Connected load 40 kVA (at 400 V mains)
Power source Transformer/Rectier
Primary cable 5 m, 6 mm²
(max. cable length 30 m, 6 mm² at 400 V)
Max. welding cable extension 20 m, 95 mm²
Cooling type F (temperature controlled cooling fan)
IP-Code IP 23 (also permits operation outdoors)
Ambient temperature limits 0 °C to 40 °C
Dimension L x W x H 460 x 400 x 730 mm (without handle)
Weight 133 kg
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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 HBS welding guns A 12, A 16, A 22 and AI 06 may only be connected to this
power unit.
The intended use also implies observance of the operating manual on the welding
gun used and compliance with the intervals and conditions for inspection and main-
tenance of the power unit and the components employed.
Always check with the operating manual of your welding gun whether it may be used
with this power unit.
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.
Please refer to the operating manual of your welding gun for detailed
information on which welding elements may be used.
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16
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 modications, 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.
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8 Components of the Power Unit
8 Components of the Power Unit
8.1 Main Assemblies
1 - Solid-State-Relais 2 - Transformer
3 - Rectier 4 - Control unit
5 - Step switch
Mains alternating current is transformed in the transformer (2) and converted in the
rectier (3).
The control unit (4) synchronizes the mechanical sequence (lifting the welding ele-
ment) with the electronic control (ignition of pilot arc, ignition of main arc, sequence
of welding time). The welding time is stepless adjustable.
The type plate is located on the backside of the power unit.
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18
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
2
3
4
5
6
7
8
9
10
- Display
- Longer
- Energy control
-Shielding gas
- Automation (not available)
- Shorter
- Contact
- Trigger
- Solenoid
- Stand-by display
10A - Locked
10B - Ready for welding
The condition of the welding unit is monitored after switching-on.
After self-test, the digital display shows the last set welding time.
The welding time is shown at the display (1).
The welding time is set with the arrow keys ( longer (2) - shorter (4)).
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20
8 Components of the Power Unit
8.3 LED Display
There is a luminous indication (LED) to the left of the display:
Green The power unit is ready for welding.
Red The power unit is locked
– after welding, until there is electrical contact with the work-
piece
– if the power unit is overheated (the display shows 8 .. 2).
After a short cooling period, the work can continue.
Green lights if the solenoid of the welding gun is controlled
Green lights if the welding gun button is triggered
Yellow lights if there is electrical contact between welding element
and workpiece
This manual suits for next models
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