HBS CI 03 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
CI 03
Stud Welding Gun
92-20-254
2016

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
CI 03 Operating Manual Issue 2016-05 Order No. E-BA 92-20-254
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

©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
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 Design and Function ............................................................................... 16
9 Welding Process ...................................................................................... 17
10 Preparing the Stud Welding Gun ........................................................... 18
10.1 Mounting the Chuck .............................................................................................. 18
10.2 Setting the Welding Parameters ........................................................................... 19
Adjusting Spring Force ....................................................................................................... 20
11 Welding ..................................................................................................... 21
12 Troubleshooting ....................................................................................... 22
13 Maintenance and Care ............................................................................. 24
13.1 Cleaning ............................................................................................................... 24
13.2 Inspection and Tests ............................................................................................. 25

5
©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
Table of Contents
14 Storage ..................................................................................................... 26
15 Disposal .................................................................................................... 26
Declaration of Incorporation of partly completed Machinery .......................... 27
Service & Support ................................................................................................ 28
Index ...................................................................................................................... 29

©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
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
©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
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.

©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
8
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.

9
©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
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.

©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
10
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
©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
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

©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
12
3 Scope of Supply
3 Scope of Supply
The basic conguration of your stud welding gun contains the following parts:
No. of
pieces
Part Type Order No.
1 Stud welding gun
cable length 10 m
CI 03 92-20-254
1 Operating manual CI 03 E-BA 92-20-254
1 Double open-ended wrench AF 14/17 80-10-069
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
For example:
Accessories ISO TS
(Chuck ISO TS and double open-ended wrench)
dia. 30 mm 92-40-066A
Accessories ISO TS
(Chuck ISO TS and double open-ended wrench)
dia. 38 mm 92-40-063A
Additional accessories can be found in our extensive accessories catalogue.

13
©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
5 Technical Data
5 Technical Data
Stud welding gun Type CI 03 (for insulation)
for CD stud welding according to current standards
Welding range Cupped head pins dia. 2/2.7 mm
Pin length 9.5 to 152.4 mm
Pin material Mild steel, stainless steel
Pin type Cupped head pins
Spring force Adjustable, arresting
Welding cable 10 m
IP-Code IP 20 (protect against humidity)
Workplace noise level > 90 dB (A) may occur during welding
Ambient temperature limits 0 °C to 40 °C
Dimension L x B x H 175 x 50 x 145 mm (without cable and tripod)
Weight 0.7 kg (without cable and tripod)

©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
14
6 Intended Use
6 Intended Use
The stud welding gun has been designed exclusively for use with standardised stud
welding elements. The use of any other elements will result in the desired strength
of the welded joint being diminished.
The stud welding gun must only be connected to HBS stud welding units.
Always check with the operating manual of your stud welding unit whether this
stud welding gun may be used.
Observation of the operating manual of the stud welding unit being used is also part
of the intended use.

15
©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
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.

©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – full or partial reproduction subject to prior approval of the manufacturer
16
8 Design and Function
8 Design and Function
The body of the stud welding gun consists of a sturdy two-part plastic housing (2).
The connecting line (3) (welding cable and control cable) is supplied through the
gun handle to the gun.
Positioned at the front of the stud welding gun are the welding piston and the retai-
ning nut used to x the manual chuck.
At the front of the stud welding gun, the gun head (5) and the spacer (6) are ins-
talled.
At the rear, there is the mechanism for spring force adjustment (1).
At the front of the stud 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.
Type plate
The type plate contains the following information:
– Manufacturer
– Type
The serial number is stamped.

17
©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
9 Welding Process
9 Welding Process
This stud welding gun may only be used for capacitor discharge stud welding with
tip ignition (contact welding).
Please refer to the original operating manual of the connected stud welding unit
for the welding procedure.

©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
18
10 Preparing the Stud Welding Gun
10 Preparing the Stud Welding Gun
Prepare the stud welding gun by
– mounting the chuck
– adjusting the spring force.
Do not connect the stud welding gun to the stud welding unit until it
has been prepared.
In this way you can avoid any unintentional starting of the welding process.
10.1 Mounting the Chuck
Select a chuck suitable for your welding element.
Cupped head pin
Cupped head pin dimension Chuck (with solenoid)
Ø in mm
30 82-50-310B
28 82-50-308A
Loosen the retaining nut.
Put the chuck with loose retaining nut up to the
stop into the piston of the welding gun.
Tighten the retaining nut again with the double
open ended wrench AF 14/17.
Insert the spacer (tripod).

19
©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
10 Preparing the Stud Welding Gun
10.2 Setting the Welding Parameters
The spring force is, among others, dependent on the workpiece and welding ele-
ments used and their diameters.
The specications in the following table are guidelines.
Select the applicable parameters for spring force for your workpiece.
Stud welding units CD 1501, CDi 1502
Pegasar 500 accu Insulation
Material of
welding elements Diameter of welding elements Welding gun parameters 1)
metric imperial CI 03
D [mm] D Spring force (Scaling) *)
Material of workpiece: Mild steel (suitable for welding) / Galvanised steel (suitble for welding)
4.8 (suitable for welding) 2 14 ga 6
4.8 (suitable for welding) 2,7 12 ga 6
Material of workpiece: Alloyed steel (suitable for welding)
A2-50 2 14 ga 6
A2-50 2,7 12 ga 6
1) to be checked by test welds
*) The spring force to be set complies with the thickness of the insulating mat as well as its density (hardness).
With thick and dense insulating mats, the spring force should be raised due to the increasing friction between
the cupped head pin and the insulating material.

©HBS Bolzenschweiss-Systeme GmbH & Co. KG
All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer
20
10 Preparing the Welding Gun
Adjusting Spring Force
The adjustment piece for spring force must not be turned by more
than 360°.
Turn the adjustment piece for spring force only until you feel a noticeable resis-
tance.
Never turn the adjustment piece further with force.
Otherwise mechanical parts of the welding gun may be damaged.
1 - End ring
2 - Adjustment piece spring force
Turn the adjustment piece for spring force (2) up to the stop in „min“ direction.
Now turn the end ring of the welding gun until the „0“ position is aligned with the
„0“ position of the marking on the adjustment piece for spring force.
Now turn the adjustment piece for spring force to the selected value (see table
under point 10.2).
You thus determine the insertion rate.
The scale on the adjustment piece for spring force does not corres-
pond to any particular dimensions.
You can reduce the insertion rate of the welding piston by turning the adjustment
piece for spring force clockwise.
You can increase the insertion rate of the welding piston by turning the adjust-
ment piece for spring force counter-clockwise.