HBS IT 2002 User manual

IT 2002
Power Unit
93-66-2201
Operating Manual

ii
ii IT 2002 Order No. BA 93-66-2201 Issue 01.06.08
IT 2002 Operating Manual, Issue 06/2008 Order No. BA 93-66-2201
Customer Service in Germany:
HBS Bolzenschweiss-Systeme GmbH & Co. KG
Felix-Wankel-Strasse 18
85221 Dachau / Germany
Phone [phone]
Fax [phone]
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 2002 Order No. BA 93-66-2201 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.

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iv IT 2002 Order No. BA 93-66-2201 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 2002 Order No. BA 93-66-2201 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 Change Working Place .............................................................................. 19
4 Function ......................................................................................... 20
4.1 Components of the Power Unit .................................................................. 20
4.1.1 Power Unit ............................................................................................................. 20
4.1.2 Control Unit ............................................................................................................ 21
4.2 Keyboard and Display ................................................................................ 21
5 Stud Welding Procedure ............................................................... 22
5.1 Safety Instructions ...................................................................................... 22
5.2 Functional Principle of Stud Welding .......................................................... 25
5.2.1 Drawn-Arc Stud Welding with Ceramic Ferrule ....................................................... 27
5.2.2 Drawn-Arc Stud Welding with Shielding Gas .......................................................... 27
5.2.3 Short-Cycle Drawn-Arc Stud Welding with Shielding Gas ....................................... 28
5.2.4 Drawn-Arc Capacitor-Discharge Stud Welding ........................................................ 29
5.3 Welding Preparation ................................................................................... 29
5.4 High-strength Welds ................................................................................... 29
5.5 Determination of Welding Parameters ....................................................... 30

vi IT 2002 Order No. BA 93-66-2201 Issue 01.06.08
5.6 Switching on the Power Unit ...................................................................... 31
5.6.1 Adjusting the Welding Time ................................................................................... 32
5.6.2 Adjusting the Welding Current ................................................................................ 32
5.6.3 Library Mode .......................................................................................................... 33
5.6.4 Conversion Current Curve ....................................................................................... 33
5.7 Welding Procedure .................................................................................... 34
5.8 Checking the Quality of the Weld ............................................................... 35
5.8.1 Visual Inspection ................................................................................................... 35
5.8.2 Bending Test .......................................................................................................... 36
5.8.3 Arc Blow Effect ...................................................................................................... 38
5.9 Malfunctions and Corrective Actions .......................................................... 39
6 Switching off the Power Unit ........................................................ 40
6.1 Temporary Switching off ............................................................................. 40
6.2 Disposal ..................................................................................................... 40
7 Care and Maintenance .................................................................. 41
7.1 Safety Instructions ...................................................................................... 41
7.2 Regular Maintenance Operations ............................................................... 41
7.3 Tools to be Used ......................................................................................... 41
7.4 Open the Power Unit .................................................................................. 42
8 Appendix ........................................................................................ 43
8.1 Technical Data............................................................................................ 43
8.2 Spare Parts ................................................................................................ 44
8.3 Circuit Diagram .......................................................................................... 56
8.4 Environmentally Admissible Disposal ......................................................... 57

IT 2002 Order No. BA 93-66-2201 Issue 01.06.08 vii
Glossary ......................................................................................... 58
Regulations and Standards .......................................................... 59
Further Instructions ....................................................................... 61
Guarantee Clauses ........................................................................ 62
Confirmation .................................................................................. 63
Feedback ........................................................................................ 64
Service & Support ......................................................................... 65
Index ............................................................................................... 66

viii IT 2002 Order No. BA 93-66-2201 Issue 01.06.08

IT 2002 Order No BA 93-66-2201 Issue 01.06.08 9
1 General
Persons addressed by this operating manual
Thisoperatingmanualiswrittenforoperators,personneloftheenduser,andauthorized
servicetechnicians.Itprovidesyouwithallnecessaryinformationtooperatethepower
unit.
Required user qualification
The power unit must only be operated by qualied personnel.
Let the power unit only be operated by persons who
– arequaliedthrough asuitable trainingaccording tothecurrentstandards(see
appendix),
– areproperlyinstructed,
– are physically and intellectually suitable,
– can be expected to reliably fulll the requested job.
What else must the owner observe?
Make sure that this operating manual is always in reach of the stud welding unit.
Readthe entire manual before operating the power unit.
Strictly observe the safety instructions.
Before starting up the power unit, let the operator sign the conrmation 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,acompanyspecicworkorder,aswellasacompany
specicmaintenance instruction must be drawn up.Thecompany specic work 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,
maintenanceetc. observe the information given inthisoperating manual.

10 IT 2002 Order No BA 93-66-2201 Issue 01.06.08
1.1 Guide to this Operating Manual
Thisoperatingmanualprovidesyouwiththefollowinginformation
"Delivery" in Chapter 2
"Starting-up" in Chapter 3
"FunctionalPrinciple" in Chapter 4
"Stud Welding Process" in Chapter 5
"Switching o the Power Unit" 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 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.

IT 2002 Order No BA 93-66-2201 Issue 01.06.08 11
1.2 Safety Symbols
Symbols and markings used in this operating manual mean:
Threat to life or risk of personal injury
Risk of material damage
Ban for persons fitted with a pace maker
Warning of dangerous electrical voltage
Warning of electromagnetic fields
Wear protective clothes
Wear protective goggles
Wear ear protection
Additional tips for operation and service safety
Prompt
–List

12 IT 2002 Order No BA 93-66-2201 Issue 01.06.08
1.3 General Safety Instructions
Improper operation of the power unit is LIFE-THREATENING!
Threat to life
– by electric shock and arc
– by toxic vapors and airborne particles
– by red-hot metal spatters (fire risk)
– by blow-up of explosive gases and materials
– by strong magnetic fields for persons fitted with a pace maker
In addition, through improper use damage to the stud welding unit
and to material can be caused. For details, see chapters 1, 3 and 5.
1.4 Intended Use
Warning: Unauthorized interference with the stud welding unit
as well as unauthorized alteration of the stud welding unit are
prohibited and result in complete cancellation of any guarantee
and liability claims against HBS.
Operation of the power unit is only allowed with HBS welding
guns, this clause is also part of ”use as directed”.
Thepowerunitisintendedtoweldweldingelementsaccordingtoactualstandards(see
chapter 5 and appendix). Any other use is regarded as not used as directed. The
manufacturerisnotliablefordamagesresultingfromthestudweldingunitnotusedas
directed. Any risk is carried by the user.
The power unit is designed according to specic standards and accident prevention
regulations. Basics are European Union guidelines and in Germany valid standards.
Please note that in your country additional standards and safety conditions (especially
rules for accident prevention) may differ from the standards mentioned in this operating
manual.Thepowerunitwasmanufacturedtothelatestdevelopmentsintechnologyand
is regarded as safe to operate (place of operation see section 8.1).
TheweldinggunsA16,A22andA25canbeconnectedtotheHBSpowerunit IT 2002.
For details please contact the HBS customer service (address see page ii).
Check in any case the operating manual of the HBS welding gun whether this
power unit can be used.
Observing the operating manual of the used welding gun is also part of the ”use as
directed”.

IT 2002 Order No BA 93-66-2201 Issue 01.06.08 13
1.5 Transportation, Packaging, Storage
HBS delivers products in a specific transport package.
Save the undamaged packing. Ship and transport the device only in its original
packing.
Right before delivery, the power unit is once again checked for proper functioning and
a control mark is attached. When receiving the delivery, check everything for damages
and completeness. If damages occurred during transportation or components are
missing, inform the manufacturer or the haulier immediately (see page ii).
Proper functioning of the power unit can only be checked before starting-up by visual
inspection (visible damage).
The following items are to be observed if the power unit is not to be put into operation
immediately after delivery.
– The power unit must be stored in a secure place
– The power unit must be protected against humidity, dust, metallic dirt.
– Storage temperature: -5 °C to +50 °C
– Relative humidity: 0% to 50% at +40 °C
0% to 90% at +20 °C
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.
If you resell the power unit, please provide us with the name and postal address
of the new owner so that we can advise them of any changes to the operating
manual.
1.6 Accompanying Documents
In addition to this operating manual, you must observe the operating manual of the
welding gun as well as applicable accident prevention and safety instructions.

14 IT 2002 Order No BA 93-66-2201 Issue 01.06.08
1.7 Markings
There are various markings and safety symbols attached to your power unit (see
section 8.1).
Make sure that all markings remain clearly visible.
Type plate
The type plate contains the following data:
Manufacturer
Type
Order No./Serial No.
Primary voltage
Fuse
Power consumption
Cooling class
Protection class
Date
Safety symbols
Replace illegible or damaged markings
Before opening machine disconnect mains
Observe operating manual
Warning of dangerous electrical voltage
Secure the following safety symbols in the area of welding place:

IT 2002 Order No BA 93-66-2201 Issue 01.06.08 15
2 Delivery
The basic equipment of your power unit contains the following components:
No. of pieces Part Type Order No.
1Powerunit IT 2002 93-66-2201
1OperatingManual IT 2002 BA 93-66-2201

16 IT 2002 Order No BA 93-66-2201 Issue 01.06.08
3 Starting-up
Inthischapteryoulearnwhattoobserveduringsetting-upandstarting-upofthepower
unit.
3.1 Requirements of Workplace
Vapors and airborne particles may occur during stud welding
operations. Especially with surface treated materials, toxic
vapors may be produced.
Ensure that a fume extraction is available and that the room is adequately
ventilatedaccordingtoaccidentpreventionregulations.
If possible, do not weld in rooms which are lower than 3 meters.
Specialregulations apply for conned rooms, accordingtoaccident prevention
regulationsof the ocial bodies (see appendix).
Weld only in adequate distance from combustible articles or liquids.
Before you start welding, remove any combustible articles or liquids in vicinity of
theworkplace.
Make sure that a re extinguisher is within reach.
Never weld in rooms exposed to risk of explosion.
Do not set-up the product in the vicinity of any apparatus or equipment which is
sensitive to welding spatters.
Do not set-up the product in the vicinity of any apparatus or equipment which is
sensitive to magnetic elds.
Set-up the power unit:
– on a stable, clean, and level surface
– so that no-one is inuenced or injured by welding spatters
– so that all cables and primary lines are protected from being damaged
– so that nobody will trip or fall over the cables or connection lines.
Ensure that air is able to circulate freely through the housing.
If heat is built-up inside the housing caused by bad air circulati-
on, the stud welding unit will be seriously damaged.

IT 2002 Order No BA 93-66-2201 Issue 01.06.08 17
Secure the following safety symbols in the area of welding place:
THREAT TO LIFE to persons fitted with a pace maker
Strong electro-magnetic fields occur in the vicinity of the stud welding
unit during welding. Such fields may affect the proper function of a
pace maker. Thus persons equipped with a pace maker must not
operate the stud welding unit and must not stay in its vicinity during
welding.
During the actual welding process, you must expect red-hot welding
spatters, possibly liquid spatters, a flash, 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
standards (see appendix).
3.2 Connecting the Power Unit to the Primary Power Supply
Comparethe primary voltage specied onthetype plate with the voltageprovided
by your primary power supply. The type plate is located on the backside of the
powerunit.
Never connect the welder to a power supply with a voltage
different from the voltage indicated on the type plate.
Check the current consumption specied on the type plate with the fuse rating of
your primary power supply.
Have an electrician check whether the outlet to which you want to connect the
power unit is correctly grounded.
Switch o the power unit.
Insert the primary plug into the checked outlet.

18 IT 2002 Order No BA 93-66-2201 Issue 01.06.08
3.3 Connecting the Welding Gun to the Power Unit
Switch off the power unit. In this way, you avoid any risk of
electrical shock.
Plug the welding cable of the welding gun into the socket of the power unit.
Press-in the plug and twist rmly clockwise.
The connection is not secured against working itself loose!
Check the plug connections regularly to ensure that they are
properly locked. In case of loose connection, heat may build up
in the plug and may destroy the entire plug connection.
Plug the control cable in the connector of the power unit.
Twist the retaining nut of the control cable connector clockwise to secure the
connection.
The welding gun cables must not be coiled during welding.
Coiled cables work as a coil and may negatively affect the
welding result. Before welding, lay out the cables lengthwise.
Fix the cables. Strong magnetic elds occur during welding which may cause a
movement of the cables. This may cause a slackness of the connections.

IT 2002 Order No BA 93-66-2201 Issue 01.06.08 19
3.4 Ground Connection
Plug the ground cable in the connector of the power unit.
Press in the plug and twist rmly clockwise.
The connection is not secured against working itself loose!
Check the plug connections regularly to ensure that they are
properly locked. In case of loose connection, heat may build up
in the plug and may destroy the entire plug connection.
Remove any rust, paint, or contaminants from the workpiece in the areas where
you intend to connect the ground cables.
Connect the ground clamps to the workpiece as securely as possible.
Take care to ensure good contact and symmetrical connection.
The welding location must lie directly between the two ground
clamps.
3.5 Change Working Place
Switch off the power unit. In this way, you avoid any risk of
electrical shock.
When you move your workplace, disconnect the welding gun and the ground
cables from the power unit. Proceed in reversed sequence as described in
sections 3.2, 3.3 and 3.4.
After changing the workplace, check the welding gun and the ground cables for
possible damage or missing components.

20 IT 2002 Order No BA 93-66-2201 Issue 01.06.08
4 Function
In this chapter you learn more about the design of the power unit and how to
use the various setting options.
4.1 Components of the Power Unit
4.1.1 Power Unit
The power unit consists of the main assemblies
1 - Mains switch 6 - Controlunit
2 - EMC-lter 7- IGBTswitch
3 - Bridge rectier 8 - Middle-frequencytransformer
withdiodes
4 - Electrolytic capacitors 9 - Welding current stabilizer
5 - Controlunit
Afterpassingthemainsswitch(1)andtheEMC-lter(2),themainsalternatingcurrent
is converted in the bridge rectier (3).
The rectied voltage is smoothed by the electrolytic capacitors (4) and transferred to
theIGBTswitches(7).Theseswitchesconvertthedirectcurrentintoahigh-frequency
alternating current of 30 kHz.
The energy is transferred via the middle-frequency transformer with diodes (8) and
rectied.
The stabilizer (9) smoothes the current and passes it on to the welding sleeves.
Control of the IGBT switches (7) is carried out by the control unit (6).