HBS CDi 3102 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
CDi 3102
Stud Welding Unit
92-10-3102B
2017

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
CDi 3102 Operating Manual Issue 2017-01 Order No. E-BA 92-10-3102B
Translation of the Original Operating Manual
Please keep the manual in a safe place for future reference.
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 machine from HBS Bolzenschweiss-Syste-
me.
We at HBS wish you success at all times when working with this stud welding ma-
chine.
The high level of quality of our products is guaranteed by 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 should you have any suggestions 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 .............................................................................................. 12
5 Technical Data .......................................................................................... 13
6 Intended Use ............................................................................................ 14
7 Warranty ................................................................................................... 15
8 Components of the Stud Welding Unit .................................................. 16
8.1 Main Assemblies ................................................................................................... 16
8.2 Control Panel and Display .................................................................................... 18
8.3 LED Display .......................................................................................................... 20
9 Welding Process ...................................................................................... 21
9.1 Contact Stud Welding ........................................................................................... 21
9.2 Gap Stud Welding ................................................................................................ 23
10 Preparing Workplace and Welding Process .......................................... 24
10.1 Preparing Surfaces ............................................................................................... 25
10.2 Checking the Stud Welding Gun .......................................................................... 26
11 Connection ............................................................................................... 27
11.1 Connecting the Welding Gun to the Stud Welding Unit ........................................ 28
11.2 Connecting the Ground Cable .............................................................................. 28
11.3 Connecting the Stud Welding Unit to the Mains Supply ....................................... 30

5
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Table of Contents
12 Welding ..................................................................................................... 31
12.1 Switching on the Stud Welding Unit ..................................................................... 31
12.2 Determining the Charging Voltage ........................................................................ 32
12.3 Setting the Charging Voltage ................................................................................ 35
12.4 Performing the Welding Process .......................................................................... 35
13 Checking the Quality of the Weld ........................................................... 39
13.1 Carrying out Visual Inspection .............................................................................. 39
13.2 Carrying out Bending Test .................................................................................... 40
13.3 Optimisation of Welding Parameters .................................................................... 42
13.4 Blowing Effect and Remedies ............................................................................... 43
14 Troubleshooting ....................................................................................... 44
15 Shutting Down ......................................................................................... 47
16 Maintenance and Care ............................................................................. 48
16.1 Cleaning ............................................................................................................... 48
16.2 Inspection and Tests ............................................................................................. 49
17 Storage ..................................................................................................... 50
18 Disposal .................................................................................................... 50
EC Declaration of Conformity ............................................................................. 51
Service & Support ................................................................................................ 52
Index ...................................................................................................................... 53

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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 techni-
cal training, know-how and experience and knowledge of applicable regulations are
able to assess the work assigned to them and recognise potential hazards.
Danger from incorrect use
Use the stud welding machine only for the purpose described in this ma-
nual.
Otherwise you may endanger yourself or damage the stud welding machine.
You endanger yourself and others if you operate the stud welding machine
incorrectly 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 machine 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 machine when you are under the inu-
ence of
– Alcohol,
– Drugs or
– Medication.
Danger from unauthorised modications
Never modify the stud welding machine or parts thereof without obtaining
a clearance certicate from the manufacturer.
You will otherwise endanger yourself. This can lead to serious injury or ex-
tensive material damage.

7
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1 Important Safety Precautions
Life-threatening danger for wearers of active implanted cardiac
devices
Never operate the stud welding machine if you wear a heart pace-
maker or implanted debrillator.
In this case, never remain in the vicinity of the stud welding machine
during welding.
Never operate the stud welding machine if persons with heart pace-
makers or implanted debrillators are in the vicinity.
Strong electromagnetic elds are produced in the vicinity of the stud
welding machine during welding. These elds could impact the func-
tion of heart pacemakers or implanted debrillators.
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 parti-
culates.
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 work-
place.

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1 Important Safety Precautions
Do not weld when wearing working clothes soiled with ammable
substances such as oil, grease, petroleum, etc.
Wear your proper protective clothing, such as:
– Protective gloves in accordance with the relevant standard,
– Non-ammable clothing,
– A protective apron over your clothing,
– Full-ear hearing protection in accordance with the relevant stan-
dard,
– A safety helmet when welding above your head,
– Safety shoes,
– Safety goggles with sight glass of protection level 2 in compli-
ance with the applicable standards and do not look directly into
the light arc.
Remove all ammable materials and liquids from the vicinity of the
work area before starting welding.
Weld at a safe distance from 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 machine against the ingress of foreign
matter and liquids caused by cutting or grinding work in the vicinity
of your work area.
This will help to prolong the service life of your stud welding machine.

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2 Symbols and Terms Used
2 Symbols and Terms Used
The symbols used in this operating manual have the following meanings:
Danger
Warns you of hazards that can lead to injury of persons or to
considerable material damage.
Caution
Problems with the operating procedures can occur if this information is
not observed.
No access for people with active implanted cardiac devices
Danger
Warns you of electrical hazards
Danger
Warns you of electromagnetic elds that can be generated during welding
These symbols prompt you to wear personal protective clothing when
working with the stud welding unit.
This symbol prompts you to wear ear protection. A loud bang > 90 dB (A)
can occur during the welding process.

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

11
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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.
Rectier: Electrical component that converts alternating vol-
tage into direct voltage
Stud feeder: Device for automatic feeding of welding elements
Stud welding gun: Device for welding of welding elements
Stud welding machine: Stud welding unit including stud welding gun
Stud welding unit: Device for provision of the electrical energy for
stud welding
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 parameters: Mechanical and electrical settings at the stud wel-
ding gun and at the stud welding unit (e.g. spring
force, charging 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 stud welding unit contains the following parts:
No. of
pieces
Part Type Order No.
1 Stud welding unit CDi 3102 92-10-3102B
1 Operating manual CDi 3102 E-BA 92-10-3102B
Inspect the shipment for visible damage and completeness immediately on re-
ceipt.
Report any transport damage or missing components immediately to the delive-
ring shipping agent or the dealer (address, see page 2).
4 Accessories
The following ground cables are available as accessories:
No. of
pieces
Part Type Order No.
1 Ground cable for C 08/CA 08
2.5 m, 25 mm²
92-40-095

13
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5 Technical Data
5 Technical Data
Stud Welding Unit CDi 3102 (with digital display)
for CD stud welding (capacitor discharge welding) according to current standards
Welding range Studs M3 to M10, dia. 3 to 10 mm
Welding material Mild steel, stainless steel, aluminium and brass
Welding rate M3 = 20 studs/min. (Charging voltage 50 V)
M8 = 10 studs/min. (Charging voltage 140 V)
M10 = 6 studs/min. (Charging voltage 200 V)
Capacitance 132 000 µF
Welding time 1 to 3 ms
Energy 3 200 Ws
Charging voltage 50 to 220 V (stepless voltage regulation)
Primary power 230 V/115 V, 50/60 Hz, 10 AT
Power source Capacitor
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 480 x 205 x 250 mm (without handle)
Weight 18 kg

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6 Intended Use
6 Intended Use
Our stud welding units are designed and built exclusively for industrial use. Nonin-
dustrial use is expressly forbidden due to the lack of know-how about the welding
technology employed and the applicable standards.
The stud welding unit is intended exclusively for stud welding of standardised wel-
ding elements. Any other use will result in the desired strength of the welded joint
being reduced.
This stud welding unit can only be used with the HBS stud welding guns C 08 and
CA 08.
The intended use also implies observance of the stud welding gun operating manual
and compliance with the intervals and conditions for inspection and maintenance of
the stud welding unit and the components employed.
Always check the operating manual of your stud welding gun whether it may be
used with this stud welding 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 stud welding gun for
detailed information on which welding elements may be used.

15
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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.
Warranty entitlement shall no longer be valid if modications, changes or service
and repair work is carried out by unauthorised persons or without the knowledge of
the manufacturer. Invalidation of warranty entitlement shall also render the declara-
tion of conformity invalid. The CE marking shall be declared invalid by the manufac-
turer.
We expressly point out that only spare parts and accessories or components appro-
ved by us may be used. The same applies likewise to installed units from our sub-
suppliers.

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16
8 Components of the Stud Welding Unit
8 Components of the Stud Welding Unit
8.1 Main Assemblies
1- Charging device A - Primary supply
2 - Control B - Welding circuit
3 - Welding capacitors
4 - Welding thyristor
The mains alternating voltage is converted to direct voltage in the charging de-
vice (1). Charging of the welding capacitors (3) is performed with the charging
device and is fully adjustable. The welding capacitors store the energy required for
the welding process. The quantity of energy is dened by the operator via the char-
ging voltage.
The welding thyristor (4) releases the charging voltage.
The charging process and the welding process are controlled by the control sys-
tem (2).
The negative pole of the capacitor is connected to the welding gun. The positive
pole is usually connected to the workpiece via vice grips.
The type plate is located on the backside of the stud welding unit.

17
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8 Components of the Stud Welding 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 Stud Welding Unit
8.2 Control Panel and Display
1
2
3
4
56789
10A
10B
1 - Display
2 - Higher
3 - Library mode
(stud diameter)
4 - Automatic mode (not available)
5 - Lower
6 - Solenoid
7 - Trigger
8 - Contact
9 - Locked
10 - Stand-by display
10A - ready for welding
10B - charging the capacitor
battery
The condition of the welding unit is monitored after switching-on. The display shows
three bars and the following parameters are monitored:
– Deviation from usual charging time,
– Unit temperature,
– Defective thyristor,
– Control discharge relay.
After the self-test, the charging voltage last set is shown in the display. During the
self-test, an automatic self-formation of the capacitors is performed, among other
things. The self-formation is a step-by-step loading of the capacitors in a certain
amount of time. This function contributes to longer capacitor service life. If the char-
ging voltage last set is above 100 V, an automatic self-formation of the capacitors is
performed during the self-test.The charging voltage is shown at the display (1).
The charging voltage is set with the arrow keys ( higher (2) - lower (4)).

19
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8 Components of the Stud Welding Unit
The stud welding unit is equipped with a library mode (3). In the library mode, the
factory default setting of charging voltages, depending on stud diameter can be
called up and modied.
This library mode only applies tho the workpiece material mild steel (suitable for
welding) and the welding element material 4.8 (suitable for welding) and only when
using the welding guns C 08 and CA 08.
The following values are stored in the library mode:
Material
of welding elements Diameter of welding elements Charging voltage
CDi 3102
in V
Welding rate
in studs/min
metric
PT, UT IT
Material of workpiece: Mild steel (suitable for welding)
4.8 (suitable for welding) M3, 3 mm -- 50 20
4.8 (suitable for welding) M4, 4 mm -- 60 19
4.8 (suitable for welding) M5, 5 mm 5 mm, M3 80 16
4.8 (suitable for welding) M6, 6 mm 6 mm, M4 110 13
4.8 (suitable for welding) M8, 7.1 mm 7.1 mm, M5 150 9
4.8 (suitable for welding) M10, 10 mm -- 210 6
If both arrow keys ( ) are simultaneously pressed for about one second, the
display shows 0. .3. (3 means the charging voltage for stud diameter M3).
The stud diameter (M3 to M10) can be pre-selected with both arrow keys ( high-
er - lower). After about 5 seconds the display jumps onto the pre-selected char-
ging voltage. The capacitor battery is charged with this value.
In addition, the charging voltage can be modied individually by pressing the arrow
key.

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20
8 Components of the Stud Welding Unit
8.3 LED Display
Green The stud welding unit is ready for welding
Red The capacitor battery is charged.
Red The stud welding unit is locked
– after welding, until there is electrical contact with the work-
piece
– if the stud welding unit is overheated. After a short cooling
period, the work can be continued.
– if thyristor is defective
– in the case of a charging malfunction (exceeding the char-
ging period)
– if arrow keys jam
– when appealing the library mode (stud diameter)
Yellow if there is electrical contact between welding element and
workpiece
Yellow if the welding gun button is triggered
Yellow if a welding gun with solenoid is connected
If one of the parameters referred to under point 8.2 “ Keyboard and Display” devi-
ates from the standard value an error message will be shown on the display.