HURNER HST 300 Junior + 2.0 User manual

Version April 2016
Nieder-Ohmener Str. 26
35325 Mücke (Atzenhain)
HÜRNER SCHWEISSTECHNIK GmbH
User’s Manual
HST 300 Junior+ 2.0
HST 300 Junior 2.0
Inliegende deutsche Fassung der Anleitung ist der Urtext, welchen inliegende Übersetzungen wiedergeben.
The German version of the manual enclosed herein is the original copy, reected in both translations herein.
La version allemande ci-après représente le texte original du manuel, rendu par les deux traductions ci-joint.

Version April 2016 EN 3 HÜRNER HST 300 Junior+ 2.0 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
Contents
1 Introduction.................................................................................. 5
2 Safety Messages............................................................................ 5
2.1 Using the Correct Connection Terminal ...................................... 5
2.2 Improper Use of the Welding and Power Supply Cables ........... 5
2.3 Securing the Fitting and the Joint............................................... 6
2.4 Cleaning the Product.................................................................... 6
2.5 Opening the Unit.......................................................................... 6
2.6 Extension Cables on the Worksite ............................................... 6
2.7 Checking the Product for Damage .............................................. 6
2.8 General Remark............................................................................ 6
2.9 PowerSupplySpecications ........................................................ 7
2.9.1 Mains Power Supply ..................................................................... 7
2.9.2 Generator Power Supply.............................................................. 7
3 Service and Repair ........................................................................ 8
3.1 General.......................................................................................... 8
3.2 Transport, Storage, Shipment ...................................................... 8
4 Principles of Operation ................................................................ 8
5 Check-out and Operation ............................................................ 9
5.1 Turning the Welding Unit on....................................................... 9
5.2 Connecting the Fitting ................................................................. 9
5.3 Reading the Fitting Code with a Handheld Scanner................ 10
5.4 Starting the Welding Process..................................................... 10
5.5 Welding Process.......................................................................... 10
5.6 End of Welding........................................................................... 11
5.7 Aborted Welding Process........................................................... 11
5.8 Cooling Time............................................................................... 11
5.9 Returning to the Start of Parameter Input ............................... 11
5.10 Using ViewWeld to View Welding Reports............................... 11
6 Entering Welding Parameters Manually
(only for model version HST 300 Junior+ 2.0) ......................... 11
6.1 Manually Entering Welding Voltage and Time ........................ 12
6.2 Entering the String of Numbers ................................................ 12
7 Dedicated Welding Unit Information........................................ 12
7.1 Displaying Characteristics of the Welding Unit ........................ 12
7.2 Measuring Resistance................................................................. 13

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4 EN HÜRNER HST 300 Junior+ 2.0 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
7.3 Overheating Switch.................................................................... 13
7.4 Indication of Power Supply Failure at the Last Welding.......... 13
8 ConguringtheWeldingUnit................................................... 13
8.1 Selecting the Display Language................................................. 14
8.2 Setting the Clock ........................................................................ 14
8.3 Setting the Buzzer Volume ........................................................ 15
8.4 Selecting the Temperature Unit and Entering the
Inventory Number ...................................................................... 15
9 Self-Monitoring Functions Overview......................................... 15
9.1 Errors During Data Input............................................................ 15
9.1.1 Code Error................................................................................... 15
9.1.2 No Contact .................................................................................. 15
9.1.3 Low Voltage................................................................................ 15
9.1.4 Overvoltage ................................................................................ 15
9.1.5 Overheated ................................................................................. 15
9.1.6 System Error................................................................................ 16
9.1.7 Temperature Error ...................................................................... 16
9.1.8 Temperatur Sensor Defective..................................................... 16
9.1.9 Clock Error................................................................................... 16
9.1.10 Unit to Service............................................................................. 16
9.1.11 Input Error................................................................................... 16
9.2 Errors During Welding................................................................ 16
9.2.1 Low Voltage................................................................................ 16
9.2.2 Overvoltage ................................................................................ 17
9.2.3 Resistance Error .......................................................................... 17
9.2.4 Frequency Error .......................................................................... 17
9.2.5 Voltage Error............................................................................... 17
9.2.6 Low Current ................................................................................ 17
9.2.7 Excess Current............................................................................. 17
9.2.8 Emergency Off ............................................................................ 17
9.2.9 Heater Coil Error......................................................................... 17
9.2.10 Power Supply Failure at Last Welding....................................... 17
10 TechnicalSpecications.............................................................. 18
11 Service and Repair Contact ........................................................ 18
12 Accessories/Parts for the Product............................................... 18

Version April 2016 EN 5 HÜRNER HST 300 Junior+ 2.0 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
1 Introduction
Dear Customer:
Thank you very much for purchasing our product. We are
confident that it will meet your expectations.
The Welding Unit, in the model version HST 300 Junior + 2.0
and HST 300 Junior 2.0, is designed exclusively for welding
plastic pipe fittings according to the electrofusion process.
It represents the next generation of the tried and tested
HST 300 series, featuring a broader range of functions.
The product was manufactured and checked according to
state-of-the-art technology and widely recognized safety
regulations and is equipped with the appropriate safety
features.
Before shipment, it was checked for operation reliability
and safety. In the event of errors of handling or misuse,
however, the following may be exposed to hazards:
• the operator’s health,
• the product and other hardware of the operator,
• the efficient work of the product.
All persons involved in the installation, operation, main-
tenance, and service of the product have to
• be properly qualified,
• operate the product only when observed,
• read carefully and conform to the User’s Manual before
working with the product.
Thank you.
2 Safety Messages
2.1 Using the Correct Connection Terminal
Use the appropriate connection terminal that is compat-
ible with the fitting type used. Be sure the contact is
firmly established and do not use connection terminals or
terminal adapters that are burnt or not designed for the
intended use.
2.2 Improper Use of the Welding and Power Supply
Cables
Do not carry the product by its cables and do not pull the
power cord to unplug the unit from the socket. Protect
the cables against heat, oil, and cutting edges.

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6 EN HÜRNER HST 300 Junior+ 2.0 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
2.3 Securing the Fitting and the Joint
Use positioner clamps or a vice to secure the fitting and
the joint to be made before welding. The fitting manufac-
turer’s installation instructions, local and national regula-
tions have to be respected in all cases.
A welding process must never be repeated with the same
fitting, since this may cause parts under power to be ac-
cessible to the touch.
2.4 Cleaning the Product
The product must not be sprayed with or immersed in
water.
2.5 Opening the Unit
Caution
The cover of the product may be removed only by
specialized staff of the manufacturer or of a service
shop properly trained and approved by it.
2.6 Extension Cables on the Worksite
To extend power cord length, use exclusively properly ap-
proved extension cables that are labeled as such and have
the following conductor sections:
up to 20 m: 1.5 mm² (2.5 mm² recommended);
Type H07RN-F
over 20 m: 2.5 mm² (4.0 mm² recommended);
Type H07RN-F
Caution
When using the extension cable, it has always to
be rolled off completely and lie fully extended.
2.7 Checking the Product for Damage
Before every use of the product, check safety features
and possibly existing parts with minor damage for proper
function. Make sure that the push-on connection terminals
work properly, that contact is fully established, and that
the contact surfaces are clean. All parts have to be installed
correctly and properly conform to all conditions in order
for the product to function as intended. Damaged safety
features or functional parts should be properly repaired
or replaced by an approved service shop.
2.8 General Remark
Comply with the indications and instructions about prod-
uct maintenance to ensure proper and safe work. Use
only accessories and spare parts that are recommended or

Version April 2016 EN 7 HÜRNER HST 300 Junior+ 2.0 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
approved by the manufacturer. Using other parts or acces-
sories may put yourself in danger of bodily injury or cause
the device to malfunction.
2.9 PowerSupplySpecications
2.9.1 Mains Power Supply
Utility suppliers’ wiring requirements, occupational safety
rules, applicable standards, and national codes have to be
respected.
Caution
When using power distributions on the worksite,
rules for the installation of earth-leakage circuit
breakers (RCD) have to be respected, and operation
requires an installed breaker.
Generator or mains power fuse protection should be max.
16 A (slow blow). The product has to be protected against
rain and humidity.
2.9.2 Generator Power Supply
The required nominal generator capacity as determined
by the power supply requirement of the largest fitting to
be welded depends on the power supply specifications,
the environment conditions, and the generator type itself
including its control/regulation characteristics.
Nominal output power of a generator 1-phase, 220 - 240 V,
50/60 Hz:
d 20.....d 160 3.2 kW
d 160....d 450 4 kW mechanically regulated
5 kW electronically regulated
Start the generator first, then connect the welding unit.
The idle voltage should be set to approx. 240 volts. When
turning the generator off, disconnect the welding unit first.
Important
The working output power of the generator de-
creases by about 10% per 1,000 m of altitude.
During the welding process no other device con-
nected to the same generator should be operated.

Version April 2016
8 EN HÜRNER HST 300 Junior+ 2.0 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
3 Service and Repair
3.1 General
As the product is used in applications that are sensitive to
safety considerations, it may be serviced and repaired only
by the manufacturer or its duly authorized and trained
partners. Thus, constantly high standards of operation
quality and safety are maintained.
Failure to comply with this provision will dispense the
manufacturer from any warranty and liability claims for
the product, including any consequential damage.
When serviced, the unit is upgraded automatically to the
technical specifications of the product at the moment it is
serviced, and we grant a three-month functional warranty
on the serviced unit.
We recommend having the product serviced at least every
twelve months.
Any provisions in the law pertaining to an electrical safety
inspection have to be complied with.
3.2 Transport, Storage, Shipment
The product ships in a transport box. The product should
be stored in this box, protects the product from humidity
and environmental agents.
When sending the product, it should be placed into the
transport box at all times.
Any provisions in the law pertaining to an electrical safety
inspection have to be complied with.
4 Principles of Operation
The HST 300 Junior + 2.0 and the HST 300 Junior 2.0 allow
welding electrofusion fittings that feature a bar code.
Every fitting is provided with a tag with one or two bar
codes on it. The structure of this code is internationally
standardized. The first code, encoding the data on proper
welding, complies with ISO TR 13950 and can be processed
with the welding unit.
The model version HST 300 Junior + 2.0 allows addition-
ally the manual input of the welding parameters. The
microprocessor-controlled welding unit:-
• controls and monitors the welding process in a fully
automated fashion,

Version April 2016 EN 9 HÜRNER HST 300 Junior+ 2.0 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
• determines welding duration depending on ambient
temperature.
The latter is done by the temperature sensor located on
the welding cable, which checks the ambient temperature
at regular intervals.
The unit monitors the characteristics of its power supply
continuously. If one of these is out of tolerance, welding
is aborted or cannot be started.
5 Check-out and Operation
• To operate the welding unit, be sure that it is set on a
proper, level surface.
• Be sure that power supply/generator protection is 16 A
(slow blow).
• Plug the power supply cord into the mains power
supply or the generator.
• Read and comply with the User’s Manual of the gen-
erator, if applicable.
5.1 Turning the Welding Unit on
After connecting the power supply cable to mains power
or a generator, turn the welding unit on using the On/Off
switch. This causes Display 1 to show.
Then the screen changes to Display 2.
Caution
CAUTION in case of System Errors!
If during the auto-test that the unit performs at
start-up, an error is detected, a “System Error” mes-
sage shows on the display. When this happens, the
welding unit has to be disconnected immediately
from the power suppy and the fitting, and it has
to be shipped to the manufacturer for repair.
5.2 Connecting the Fitting
Connect the connection terminals to the fitting and check
for proper contact. Use terminal adapters if needed. The
contact surfaces of the cable connection terminals or adapt-
ers and the fitting have to be clean. Dirty terminals may
lead to improper welding and also to overheated and fused
connection terminals. Protect the cable connectors against
getting dirty at all times. Terminals and push-on adapters
should be considered consumables and, therefore, have to
be checked before every welding operation and replaced
if damaged or dirty.
Display 1
********************
HUERNER
HST 300 Junior+ 2.0
********************
Display 2
Enter Fitting Code
14:32:11 21.10.12
Inp.Volt. 230V 50Hz
No Contact

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10 EN HÜRNER HST 300 Junior+ 2.0 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
When the fitting is connected, the “No Contact” message
(see Display 2) disappears.
5.3 Reading the Fitting Code with a Handheld
Scanner
Only the bar code on the tag sticking on the fitting to be
welded may be used. It is not acceptable to read the fitting
code tag of a fitting of a different kind if the intended
one is damaged or unreadable.
Read the fitting code by holding the scanner in front of
the bar code at a distance of 5 to 10 cm (2 to 4 inches),
where the red line indicates the reading area. Then push
the reading button. If the data are correctly read, the weld-
ing unit confirms this by an audible signal and displays the
decoded data on the screen (see Display 3).
Info
The displayed values are the nominal welding
parameters contained in the fitting bar code or
computed based on these data. They are displayed
before the actual resistance of the electrofusion
fitting is measured. This means that even when
the showing ohm value is o.k., a resistance error
may still be detected (see Sect. 7.2). Only when
the welding process starts, the display shows the
actual, measured welding parameters.
The “Start ?” message means that the unit is ready to start
the welding process. Check the read data and if you see
that they are erroneous, delete them by pressing the STOP/
RESET key. The read data are also deleted if the welding
unit is disconnected from the fitting.
5.4 Starting the Welding Process
After reading or entering the fitting code, the welding
process can be started using the START/SET key, when the
“Start ?” message is displayed and there is no indication
of a problem.
Pressing the START/SET key will trigger a confirmation mes-
sage “Pipe treated?,” which in turn requires a confirmation
with the START/SET key to start the welding proper.
5.5 Welding Process
The welding process is monitored for its entire duration
applying the welding parameters contained in the fitting
code. The welding voltage, the resistance, and the weld-
ing current are displayed in the lower line of the screen.
Display 3
Start ?
Temp.: 20°C
HST 315mm 58s
MON 35.00V 1.57Ω
Display 4
Act. Time: 56sec
Nom. Time: 90sec
35.00V 1.57Ω 15.94A