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CDM 3201
Operating Manual
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HBS CDM 3201 Operating Manual

CDM 3201
Power Unit
Automatic V ersion
92-12-3321A
Operating Manual
ii
CDM 3201 Operating Manual, Issue 09/2008 Order No. BA 92-12-3321A
Customer Service in Germany:
HBS Bolzenschweiss-Systeme GmbH & Co. KG Felix-Wankel-Strasse 18 85221 Dachau / Germany
Phone +49 (0) 8131 511-0 Fax +49 (0) 8131 511-100 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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CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08 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 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
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.
CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
v
Table of Contents
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, S torage ........................................................... 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 Compressed Air Connection for Automatic Stud Feeding .......................... 20
3.6 Change Working Place .............................................................................. 20
4 Function .........................................................................................21
4.1 Components of the Power Unit .................................................................. 21
4.2 Keyboard and Display ................................................................................ 22
5 Stud Welding Procedure...............................................................23
5.1 Safety Instructions...................................................................................... 23
5.2 Functional Principle of Stud Welding.......................................................... 26
5.2.1 Contact S tud Welding ............................................................................................ 26
5.2.2 Gap Stud W elding.................................................................................................. 27
5.3 Welding Preparation................................................................................... 28
5.4 High-Strength Welds .................................................................................. 28
5.5 Determination of Welding Parameters ....................................................... 28
5.6 Switching on the Power Unit ...................................................................... 30
5.6.1 Adjusting the Charging Voltage of Cap acitors......................................................... 32
5.6.2 Setting the Stud Feed Time (Automatic Mode)....................................................... 33
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CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
Table of Contents
5.6.3 Adjusting the Modes .............................................................................................. 3 3
Program mode ....................................................................................................... 33
Library mode .......................................................................................................... 34
5.6.4 Setting the Controls ............................................................................................... 35
5.6.5 Adjusting the Language.......................................................................................... 39
5.6.6 Adjusting the Lift Test (Welding Gun) ..................................................................... 39
5.6.7 Adjusting Service ................................................................................................... 40
5.6.8 Adjusting Reset ..................................................................................................... 40
5.6.9 Adjusting the Thyristor (Capacity Switch)............................................................... 41
5.6.10 Adjusting the Gas Pre-Flow Time........................................................................... 41
5.7 Welding Procedure .................................................................................... 42
5.7.1 Welding in Automatic Mode ................................................................................... 43
5.7.2 External Welding Start ........................................................................................... 44
5.7.3 Charging Monitoring (Ready) .................................................................................. 45
5.7.4 Contact .................................................................................................................. 45
5.7.5 RS232 Interface ..................................................................................................... 45
5.8 Checking the Quality of the Weld ............................................................... 4 6
5.8.1 Visual Inspection ................................................................................................... 46
5.8.2 Bending T est.......................................................................................................... 47
5.8.3 Arc Blow Effect ...................................................................................................... 49
5.9 Malfunctions and Corrective Actions ..........................................................50
5.9.1 Error Codes ........................................................................................................... 51
5.10 Welding Elements ...................................................................................... 52
6 Switching off the Power Unit ........................................................54
6.1 Temporary Switching off ............................................................................. 54
6.2 Disposal ..................................................................................................... 54
7 Care and Maintenance .................................................................. 55
7.1 Safety Instructions...................................................................................... 55
7.2 Regular Maintenance Operations............................................................... 55
7.3 Tools to be Used......................................................................................... 55
7.4 Open the Power Unit .................................................................................. 56
8 Appendix ........................................................................................58
8.1 Technical Data............................................................................................ 58
8.2 Spare Parts ................................................................................................59
8.3 Transmission of Recognized Data With Microsoft® Hyper Terminal ......... 74
8.4 Environmentally Admissible Disposal......................................................... 79
CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
vii
Table of Contents
Glossary .........................................................................................80
Regulations and Standards .......................................................... 81
Further Instructions.......................................................................83
Guarantee Clauses ........................................................................ 84
Confirmation ..................................................................................85
Feedback........................................................................................86
Service & Support ......................................................................... 87
Index ...............................................................................................88
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CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
Table of Contents
CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08 9
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 power unit.
Required user qualification
The power unit must only be operated by qualified personnel.
Let the power unit only be operated by persons who
– are qualified through a suitable training according to the current standards (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 power unit.Strictly observe the safety instructions.Before starting up the power unit, 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 power unit 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 power unit 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.
1 General
10 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
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 Power Unit" 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 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.
1 General
1.1 Guide to this Operating Manual
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
1 General
1.2 Safety Symbols
12 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
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”.
The power unit 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 stud welding unit not used as directed. Any risk is carried by the user.
The power unit 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 power unit was manufactured to the latest developments in technology and
is regarded as safe to operate (place of operation see section 8.1).
The welding guns C 08, CA 08, PAH-1 and the welding head KAH 412 can be connected to the HBS power unit CDM 3201. 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”.
1 General
1.3 General Safety Instructions
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
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.
1 General
1.5 Transportation, Packaging, Storage
14 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
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:
1 General
1.7 Markings
2 Delivery
The basic equipment of your power unit contains the following components:
No. of pieces Part Type Order No.
1 Power unit CDM 3201 92-12-3321A
1 Operating Manual CDM 3201 BA 92-12-3321A
2 Delivery
16 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
3 Starting-up
In this chapter you learn what to observe during setting-up and starting-up of the power 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
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.
Do not set-up the product in the vicinity of any apparatus or equipment which is
sensitive to magnetic fields.
Set-up the power unit:
– 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 circulati­on, the stud welding unit will be seriously damaged.
3 Starting-up
3.1 Requirements of Workplace
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
Compare the primary voltage specified on the type plate with the voltage provided
by your primary power supply. The type plate is located on the backside of the power unit.
Never connect the welder to a power supply with a voltage different from the voltage indicated on the type plate.
Check the current consumption specified 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 off the power unit.
Insert the primary plug into the checked outlet.
3 Starting-up
3.2 Connecting the Power Unit to the Primary Power Supply
18 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
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 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.
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 fields occur during welding which may cause a
movement of the cables. This may cause a slackness of the connections.
3 Starting-up
3.3 Connecting the Welding Gun to the Power Unit
3.4 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.
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 Starting-up
3.4 Ground Connection
20 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
3.5 Compressed Air Connection for Automatic Stud Feeding
If you use the automatic stud feeding unit, put the air hose of the compressed air
supply (6 bar, 800 l/min) into the feeder unit VBZ-3.
Connect the compressed air outlet of the feeding unit to the compressed air inlet
of the power unit.
An operating pressure of max. 6 bars can be set with the pressure reduction valve of the feeding unit. The filter unit cleans and drains the compressed air.
Rear view
3.6 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 section 3.2, 3.3, 3.4 and 3.5.
After changing the workplace, check the welding gun and the ground cables for
possible damage or missing components.
3 Starting-up
3.5 Compressed Air Connection for Automatic Stud Feeding
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
The power unit consists of the following main assemblies
- Charging unit (1) - Control (2)
- Welding capacitors (3) - Welding thyristor (4)
Mains alternating current is converted into direct current in the rectifier (1). Welding capacitors (3) are charged to the adjusted voltage. The capacitors store the energy which is required for the welding process. The total energy is set by the user via the charging voltage.
The electronic switch (4) releases the charging voltage in the right time.
The charging process as well as the welding process are controlled by the control unit (2).
The negative pole of the capacitor is connected to the welding gun.
The positive pole is mostly connected to the work piece via the vice grips.
4 Function
4.1 Components of the Power Unit
22 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
4.2 Keyboard and Display
The terminal is the interface with the user. You are provided with information about the state of the power unit via the display. You can program the power unit with the keys according to your requirements.
How to use displays and keys is described in section 5.6.
4 Function
4.2 Keyboard and Display
5 Stud Welding Procedure
This chapter contains the basics of stud welding, how you must actually proceed, and what must be observed. You learn to select correct welding parameters and which welding elements can be used.
5.1 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 – during welding of hollow parts – by strong magnetic fields to persons fitted with a pace maker
THREAT TO LIFE by electrical shock and arc
During the actual stud welding process, do not touch the welding elements, chuck, or retaining nut nor any electrically conductive parts in their vicinity. These are all electrically life.
Step onto an insulating mat, if you have to weld under the following conditions:
– in confined rooms with electrically conductive walls – under confined conditions between or on electrically conductive
parts
– with restricted freedom of movement on electrically conductive
parts – in wet or hot areas When operating the stud welding unit, you must not wear any metallic
jewellery incl. wrist watches, especially on hands. Remove any electrically conductive or electro-magnetically sensitive parts from your body before you start welding. In this way, you avoid the risk of damage by electric shock or influence of electromagnetic fields.
5 Stud Welding Procedure
5.1 Safety Instructions
24 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
THREAT TO LIFE by toxic vapors and airborne particles
Toxic vapors and airborne particles may occur during stud welding operations, especially with surface treated materials.
Ensure that a fume extraction is available 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 of your country (see appendix).
THREAT TO LIFE by red-hot metal spatters (fire risk)
Make sure that a fire extinguisher is within reach. Do not wear clothes, which are contaminated with combustible
materials like oil, grease, kerosene etc. during welding. Always wear your personal protective equipment such as: – protective gloves to current standards (see appendix), – safety goggles with a window providing protection class 2 to
current standards (see appendix),
– non-combustible clothes – ear protection to current standards (see appendix), – a protective apron over your clothes, – a protective headgear when welding overhead. Before starting to weld, remove all combustible articles and liquids in
vicinity of the workplace. Weld only in sufficient distance from combustible articles or liquids.
choose a safety distance where there is no risk to injury from welding spatters!
THREAT TO LIFE by blow-up of explosive gases and materials
Never weld in rooms exposed to danger by explosion. Special know-how is required when welding hollow parts which – are combustible or support combustion, – can emit toxic gases, vapors, or airborne particles, – can explode. Never execute such operations, if you do not have such special know-
how.
Observe the regulations for accident prevention and standards which apply to the use of your stud welding unit (see appendix). The official Professional Association of your country will provide you with further information.
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.
5 Stud Welding Procedure
5.1 Safety Instructions
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).
MAGNETIC FIELDS! During stud welding, strong magnetic fields are present. Do not weld in the vicinity of electrical systems and machines which could be affected.
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.
In case of any accidents whatsoever, advise a physician, your supervisor, and
the official bodies immediately.
5 Stud Welding Procedure
5.1 Safety Instructions
26 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
5.2 Functional Principle of Stud Welding
Stud welding with tip ignition is divided into gap stud welding and contact stud welding.
5.2.1 Contact Stud Welding
– The welding gun is placed onto the workpiece (figure 5.2.1, position 1). The welding
element which projects above the welding gun support legs, is pushed back tensioning a pressure spring.
– After positioning the welding gun against the workpiece, the operator triggers the
welding gun button and starts the welding process; thus the current circuit is closed.
– The capacitors of the power unit are discharged. Because of the high discharge
current, the ignition tip evaporates explosion-like. The air gap between welding element and workpiece is ionized (see figure 5.2.1, position 2), an arc is produced.
– The arc melts the face of the welding element together with an area of the workpiece
of about the same dimension (see figure 5.2.1, position 3).
– Caused by the pressure spring, the welding element moves to the workpiece with a
speed of 0,5 to 1 m/s. The adjusted spring force controls the plunging speed of the welding element.
– Higher plunging speed leads to shortened arc time and consequently to lower
welding energy with identical voltage setting.
– The arc is cut as soon as the welding element touches the workpiece.
– Now the capacitors are short-circuited and the rest of the energy drains off (see figure
5.2.1, position 4).
– The pressure spring continues to push the welding element into the weld pool. – The weld pool solidifies and the welding element is physically connected to the
workpiece.
– The time period between ignition of the arc and solidification of the weld pool is about
3 ms.
With high plunging speed of the welding element, the air gap closes after vaporization of the ignition tip faster, thus the arc time becomes shorter. With rapidly oxidizing materials like e.g. aluminum, the arc must only burn a very short time.
– The use of contact welding for rapidly oxidizing materials like aluminum and
aluminum alloys is not recommended because the arcing period with contact welding is longer than with gap stud welding.
5 Stud Welding Procedure
5.2 Functional Principle of Stud Welding
5.2.2 Gap Stud Welding
– The solenoid, which is integrated into the welding gun, lifts the welding element
from the workpiece (see figure 5.2.2, position 1) to the adjusted value ”lift” above the workpiece and tensions a pressure spring (see figure 5.2.2, position 2).
– As soon as the welding piston has reached the upper stop, the current to the solenoid
is cut. Simultaneously, the welding thyristor is triggered and releases the current flow to the welding element.
– The capacitors of the power unit are discharged. Because of the high discharge
current, the ignition tip evaporates explosion-like. The air gap between welding element and workpiece is ionized (see figure 5.2.2, position 3), an arc is produced.
– The arc melts the face of the welding element together with an area of the workpiece
of about the same dimension (see figure 5.2.2, position 4).
– The welding element is moved by the pressure spring to the workpiece with a speed
of 0,5 to 1,5 m/s. The adjusted spring force and the preset lift distance controls the plunging speed of the welding element.
– Higher plunging speed leads to shortened arc time and consequently to lower
welding energy with identical voltage setting.
– The arc is cut as soon as the welding element touches the workpiece. – Now the capacitors are short-circuited and the rest of the energy drains off (see figure
5.2.2, position 5).
– The pressure spring continues to push the welding element into the weld pool.
– The weld pool solidifies and the welding element is physically connected to the
workpiece.
– The time period between ignition of the arc and solidification of the weld pool is about
1 to 2 ms.
With high plunging speed of the welding element, the air gap closes after vaporization of the ignition tip faster, thus the arc time becomes shorter. With rapidly oxidizing materials like e.g. aluminum, the arc must only burn a very short time.
5 Stud Welding Procedure
5.2 Functional Principle of Stud Welding
28 CDM 3201 Order No. BA 92-12-3321A Issue 19.09.08
5.3 Welding Preparation
Read the safety instructions in chapters 1, 3 and 5.
Observe the workplace requirements (chapter 3, ”Starting-up").
Check all cables and connections for proper condition.
Replace immediately defective cables and cable connections to avoid electrical
shocks.
Check the chuck for proper seat (see operating manual of according welding
gun).
Before welding, make sure that the bellows are checked for damage and proper
seat.
5.4 High-Strength Welds
The following must be removed both from the weld zone and the ground clamp
connection areas:
– paint, oil and any other impurities,
– rust,
– non-conductive coatings from surface treated workpieces.
Weld to smooth and flat surfaces only.
For welding to pipes or punched plates consult our responsible application manager (address of customer service see page ii).
5.5 Determination of Welding Parameters
The adjustment of welding parameters on the power unit (e.g. charging voltage via energy controller) or on the welding gun (e.g. spring force) depends amongst others on
– material of the welding element
– diameter of the welding element
– material of the workpiece
The guidelines should be verified by test welding on the actual material and be changed if necessary. For an assessment of welding results, see section 5.8 and 5.9.
5 Stud Welding Procedure
5.3 Welding Preparation
Data given in the following table are only guidelines. They must be verified by trial welds on the actual material according to actual standards and DVS guidelines (see appendix). Before you use another lot of welding elements, carry out some trial welds to verify the parameter setting.
Material of welding element s
C 08
PT, UT IT
132.000 µF
Thy ris t or 1 + 2
66.000 µF
Thy ris t or 1
Sprin g force
(scaling)
Spring force
(sc aling)
Lift
(mm)
S235 / St 37 (4.8) M3 , 3 mm -- 1/8" #6-32 50 80 6 2 1 S235 / St 37 (4.8) M4 , 4 mm -- 5/32" #8-32 60 100 6 2 1 S235 / St 37 (4.8) M5 , 5 mm 5 mm, M3 3/16" #10-32 80 130 6 2 1, 6 S235 / St 37 (4.8) M6, 6 mm 6 mm, M4 1/ 4" 1/ 4-20 110 170 6 6 1, 6 S235 / St 37 (4.8) M8, 7, 1 mm 7,1 mm, M5 5/ 16" 5/16-18 150 220 9 6 2 S235 / St37 (4.8) M10, -- -- 3/8" 3/8-16"
210
2) 1)
962
S235 M3, 3 m m -- 1/ 8" #6-32 70 1 00 6 6 1 S235 M4, 4 m m -- 5/ 32" #8-32 110 130 6 6 1 S235 M5, 5 m m 5 mm, M3 3/16" #10-32 140 190 3 6 1 S235 M6, 6 m m 6 mm, M4 1/4" 1/4-20 170 220 3 6 1 S235 M8, 7, 1 mm 7,1 mm, M5 5/ 16" 5/16-18
220
2) 1)
-- -- --
1.4301, 1.4 303 M3, 3 m m -- 1/8 " #6-32 50 60 6 6 1,4
1.4301, 1.4 303 M4, 4 mm -- 5/32" #8-32 60 90 6 6 1,4
1.4301, 1.430 3 M5, 5 mm 5 mm, M3 3/16" #10-32 80 120 6 6 1, 6
1.4301, 1.430 3 M6, 6 mm 6 mm, M4 1/ 4" 1/ 4-20 100 160 6 6 2
1.4301, 1.430 3 M8, 7, 1 mm 7,1 mm, M5 5/ 16" 5/16-18 140 220 11 6 2
1.4301, 1.4303 M10, -- -- 3/8" 3/8-16"
200
2) 1)
11 6 2
CuZn37 M3, 3 m m -- 1/ 8" #6-32 5 0 60 6 6 1 CuZn37 M4, 4 m m -- 5/ 32" #8-32 6 0 70 6 6 1 CuZn37 M5, 5 m m -- 3/ 16" #10-32 80 120 9 -- -­CuZn37 M6, 6 m m -- 1/ 4" 1/ 4-20 110 180 9 -- -­CuZn37 M8, 7, 1 mm -- 5/1 6" 5/16-18
170
2) 1)
9----
AlMg3 M3, 3 mm -- 1/8" #6-32 50 70 6 9 1 AlMg3 M4, 4 mm -- 5/32" #8-32 60 100 6 9 1,4 AlM g3 M5, 5 m m 5 mm, M3 3/16" #10-32 90 130 6 9 2 AlM g3 M6, 6 m m 6 mm, M4 1/4" 1/4-20 120 160 11 9 2,4 AlM g3 M 8, 7, 1 mm 7,1 mm, M5 5/ 16" 5/16-18
170
2) 1) 2)
-- 9 3
CDM 3201
Charging voltage (V)
(metri c) (imperi al)
Gun paramet ers
CA 08
Mate rial of work piec e: A lumi num
Diameter of welding elements
Mate rial of work piec e: M ild s teel , s hiny S235 / St 37.3k (4.8 ) weldable
Mate rial of work piec e: S teel galvanized S 235
Mate rial of work piec e: Cr-Ni st ainles s s tee l 1.43 01, 1. 4303
Material of workpiece: Brass CuZn37
Energy
1)
power unit with higher capacity recommended
2)
to be checked by trials
Further notes on – welding elements – prestress at installation (tie load) and torque – material combinations see appendix and operating manual of the according welding gun.
5 Stud Welding Procedure
5.5 Determination of Welding Parameters
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