HBS A 12 User manual

A 12
Welding Gun
93-20-270
Operating Manual

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ii A 12 Order No. BA 93-20-270 Issue 01.03.08
A 12 Operating Manual, Issue 03/2008 Order No. BA 93-20-270
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

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A 12 Order No. BA 93-20-270 Issue 01.03.08 iii
Dear customer,
Thank you very much for purchasing a welding gun 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 A 12 Order No. BA 93-20-270 Issue 01.03.08
Your welding gun may differ in some details from the captions in this manual. This has
no effect on the operation of the welding gun.
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.

A 12 Order No. BA 93-20-270 Issue 01.03.08 v
Table of Contents
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 Adjustment of Projection (Plunging Depth)................................................. 19
4.3 Adjustment of Lift ........................................................................................ 19
4.4 Adjustment of Spring Force ........................................................................ 19
5 Stud Welding Procedure ............................................................... 21
5.1 Safety Instructions ...................................................................................... 21
5.2 Functional Principle of Stud Welding .......................................................... 24
5.2.1 Drawn-Arc Stud Welding with Ceramic Ferrule ....................................................... 26
5.2.2 Drawn-Arc Stud Welding with Shielding Gas .......................................................... 26
5.2.3 Short-Cycle Drawn-Arc Stud Welding with Shielding Gas ....................................... 27
5.2.4 Drawn-Arc Capacitor-Discharge Stud Welding ........................................................ 28
5.3 Welding Preparation ................................................................................... 28
5.4 High-strength Welds ................................................................................... 28
5.5 Determination of Welding Parameters ....................................................... 29
5.6 Welding Procedure .................................................................................... 31

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Table of Contents
5.7 Checking the Quality of the Weld ............................................................... 32
5.7.1 Visual Inspection ................................................................................................... 32
5.7.2 Bending Test .......................................................................................................... 33
5.7.3 Arc Blow Effect ...................................................................................................... 35
5.8 Malfunctions and Corrective Actions .......................................................... 36
5.9 Welding Elements ...................................................................................... 37
6 Switching off the Welding Gun ..................................................... 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 ............................................................. 42
8 Appendix ........................................................................................ 43
8.1 Technical Data ............................................................................................ 43
8.2 Spare Parts ................................................................................................ 44
8.3 Accessories ............................................................................................... 50
8.4 Environmentally Admissible Disposal ......................................................... 52
Glossary ......................................................................................... 53
Regulations and Standards .......................................................... 54
Further Instructions ....................................................................... 56
Guarantee Clauses ........................................................................ 57
EU-Statement of Conformity ......................................................... 58
Confirmation .................................................................................. 59
Feedback ........................................................................................ 60
Service & Support ......................................................................... 61
Index ............................................................................................... 62

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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 welding
gun.
Required user qualification
The welding gun must only be operated by qualified personnel.
Let the welding gun only be operated by persons who
– are qualified through a suitable training according to the current standards for stud
welding (see appendix),
– are properly instructed,
– are physically and intellectually suitable,
– can be expected to reliably fulfill 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 welding gun.
Strictly observe the safety instructions.
Before starting up the welding gun, let the operator sign the confirmation 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 welding gun against unauthorized use.
Inform our service in case of malfunction.
Based on this operating manual, a company specific work order, as well as a company
specific maintenance instruction must be drawn up. The company specific work order
must consider the special user conditions in your company.
Make sure that operators of the welder are provided with and wear personal protective
equipment, e.g. protective goggles, gloves, shoes, ear protection etc.
Owners and operators make sure that the welding gun 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.

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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 off the Welding Gun" 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 welding gun. 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.

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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

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1.3 General Safety Instructions
Improper operation of the welding gun 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 welding gun is only allowed with HBS power
units, this clause is also part of ”use as directed”.
The welding gun is intended to weld welding elements according to actual standards
(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 not used as
directed. Any risk is carried by the user.
The welding gun is designed according to specific 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. The welding gun was manufactured to the latest developments in technology
and is regarded as safe to operate (place of operation see section 8.1).
The welding gun A 12 can be connected to the HBS power units ARC 500, ARC 800,
ARC 1550, IT 90, IT 130, IT 1001 and IT 2001. For details please contact the HBS
customer service (address see page ii).
Check in any case the operating manual of the HBS power unit whether this
welding gun can be used.
Observing the operating manual of the used power unit is also part of the ”use as
directed”.

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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 welding gun 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 welding gun can only be checked before starting-up by visual
inspection (visible damage).
The following items are to be observed if the welding gun is not to be put into operation
immediately after delivery.
– The welding gun must be stored in a secure place
– The welding gun 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
If you resell the welding gun, 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 also observe the operating manual of the
power unit to which the welding gun is to be connected as well as applicable accident
prevention and safety instructions.

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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:

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2 Delivery
The basic equipment of your welding gun contains the following components:
No. of pieces Part Type Order No.
1Welding gun, cable length 5 m A 12 93-20-270
1Operating Manual A 12 BA 93-20-270

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3 Starting-up
In this chapter you learn what to observe during setting-up and starting-up of the welding
gun.
3.1 Requirements of Workplace
The welding gun corresponds with protection class IP 20. It
must not be used in a humid environment!
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
ventilated according to accident prevention regulations.
If possible, do not weld in rooms which are lower than 3 meters.
Special regulations apply for confined rooms, according to accident prevention
regulations of the official 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
the workplace.
Make sure that a fire 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 or to magnetic fields.
Work with the welding gun:
– on a stable, clean, and level surface
– so that no-one is influenced 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.

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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 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 related socket of the power
unit.
Press-in the plug and twist firmly to the right.
The connection is not secured against working itself loose!
Check plug connections regularly to ensure that they are
properly locked. In case of loose connection, heat may built up
in the plug and may destroy the entire plug connection.

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Plug in the control cable of the welding gun into the appropriate connection on
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 fields occur during welding which may cause a
movement of the cables. This may cause a slackness of the connections.
3.3 Ground Connection
Plug the ground cable in the connector of the power unit.
Press in the plug and twist firmly 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.

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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.
3.4 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 and 3.3.
After changing the workplace, check the welding gun and the ground cables for
possible damage or missing components.

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4 Function
In this chapter you learn more about the design of the welding gun and how
to use the various setting options.
4.1 Components of the Welding Gun Ceramic
The body of the welding gun consists of a sturdy two-part plastic
housing (2).
The control cable and the welding current cable (3) are connected
through the welding gun handle to the welding gun.
Positioned at the front of the welding gun are the welding piston and the
retaining nut (6) used to fix the manual chuck.
At the front of the welding gun, the face plate (5) is installed. Here the tripods, as
described in section 8.2 , are mounted.
At the rear, there is the mechanism for lift off adjustment (8), rotating graduated
ring (7) and for spring force adjustment (1).
At the front of the welding gun handle, the welding gun trigger (4) is installed. It is used
to trigger the welding process.
The serial number can be found on the welding gun handle.

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4.2 Adjustment of Projection (Plunging Depth)
Set the burnoff (plunging distance, projection). You will find reference
values in the operating manual of the power unit used.
Clamp the tripod column with the knurled screws.
4.3 Adjustment of Lift
Draw the adjustment wheel backwards out of its locking position.
By rotating the adjustment wheel counter-clockwise, you can adjust the required
lift value in steps of 0.2 mm (distance between 0 and 0,2 mm is required to set-
up the internal adjustment wheel of the length compensation device)
Now push the adjustment wheel, back into its locking position.
4.4 Adjustment of Spring Force
Rotate the adjustment wheel to the selected reference value to set the effective
pre-tensioning of the spring.
Depending on your welding job, you may change the spring tension individually.
Rotating the adjustment wheel clockwise: spring pre-tensioning of welding piston
is decreased.
Rotating the adjustment wheel counter-clockwise: spring pre-tensioning of
welding piston is increased.

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The adjustment wheel can be turned by max. 360°.
Forced turning with noticeable resistance of the adjustment
wheel can result in mechanical damage of components.
You can take reference values of the welding parameters to be adjusted, like welding
current and welding time, from the operating manual of the welding power unit to which
the stud welding gun A 12 is connected.
Switch on the power unit
Set up the welding time required for your welding task and where appropriate
welding current (see table operating manual of the unit).
Place the gun vertically onto the workpiece. The welding is released by triggering
the gun button.