HBS IT 1002 Operating Manual
IT 1002
Power Unit
CP Version
93-66-1206
Operating Manual
ii
ii IT 1002 Order No. BA 93-66-1206 Issue 03.11.08
IT 1002 Operating Manual, Issue 11/2008 Order No. BA 93-66-1206
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
iii
IT 1002 Order No. BA 93-66-1206 Issue 03.11.08 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.
iv
iv IT 1002 Order No. BA 93-66-1206 Issue 03.11.08
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.
IT 1002 Order No. BA 93-66-1206 Issue 03.11.08 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 Shielding Gas Connection .......................................................................... 20
3.6 Compressed Air Connection for Automatic Stud Feeding .......................... 21
3.7 Change Working Place .............................................................................. 21
4 Function .........................................................................................22
4.1 Components of the Power Unit ..................................................................22
4.1.1 Power Unit ............................................................................................................. 22
4.1.2 Control Unit............................................................................................................ 23
4.2 Keyboard and Display ................................................................................23
5 Stud Welding Procedure...............................................................24
5.1 Safety Instructions......................................................................................24
5.2 Functional Principle of Stud Welding..........................................................27
5.2.1 Drawn-Arc stud Welding with Ceramic Ferrule........................................................ 29
5.2.2 Drawn-Arc Stud Welding with Shielding Gas .......................................................... 30
5.2.3 Short-Cycle Drawn-Arc Stud Welding with Shielding Gas....................................... 31
5.2.4 Drawn-Arc Capacitor-Discharge Stud W elding........................................................ 31
5.3 Welding Preparation...................................................................................32
5.4 High-strength Welds................................................................................... 32
vi IT 1002 Order No. BA 93-66-1206 Issue 03.11.08
Table of Contents
5.5 Determination of Welding Parameters ....................................................... 32
5.6 Switching on the Power Unit ...................................................................... 34
5.6.1 Adjusting the Welding Time ................................................................................... 36
5.6.2 Adjusting the Welding Current................................................................................ 37
5.6.3 Adjusting the Gas Pre-Flow Time........................................................................... 37
5.6.4 Library Mode .......................................................................................................... 37
5.6.5 Electrode Mode...................................................................................................... 38
5.6.6 Adjusting the Stud Feeding T ime (Blow T ime) ........................................................ 38
5.6.7 Adjusting the Controls............................................................................................ 38
5.7 Welding Procedure .................................................................................... 43
5.7.1 Automatic Welding Mode ....................................................................................... 44
5.7.2 External Welding Start ........................................................................................... 45
5.7.3 Charging Supervision (ready).................................................................................. 46
5.7.4 Contact .................................................................................................................. 46
5.7.5 RS-232 Interface .................................................................................................... 47
5.7.6 OK/ERR................................................................................................................. 47
5.8 Checking the Quality of the Weld ............................................................... 48
5.8.1 Visual Inspection ................................................................................................... 48
5.8.2 Bending T est.......................................................................................................... 49
5.8.3 Arc Blow Effect ...................................................................................................... 51
5.9 Malfunctions and Corrective Actions .......................................................... 52
5.10 Welding Elements ...................................................................................... 53
6 Switching off the Power Unit ........................................................ 56
6.1 Temporary Switching off............................................................................. 56
6.2 Disposal ..................................................................................................... 56
7 Care and Maintenance .................................................................. 57
7.1 Safety Instructions...................................................................................... 57
7.2 Regular Maintenance Operations............................................................... 57
7.3 Tools to be Used......................................................................................... 57
7.4 Open the Power Unit .................................................................................. 58
8 Appendix ........................................................................................ 59
8.1 Technical Data............................................................................................ 59
8.2 Spare Parts ................................................................................................ 60
8.3 Circuit Diagram .......................................................................................... 74
8.4 Transmission of Recognized Data With Microsoft® Hyper Terminal ......... 75
8.5 Environmentally Admissible Disposal.........................................................80
IT 1002 Order No. BA 93-66-1206 Issue 03.11.08 vii
Table of Contents
Glossary .........................................................................................81
Regulations and Standards .......................................................... 82
Further Instructions....................................................................... 84
Guarantee Clauses ........................................................................ 8 5
Confirmation ..................................................................................86
Feedback........................................................................................ 87
Service & Support ......................................................................... 88
Index ...............................................................................................89
viii IT 1002 Order No. BA 93-66-1206 Issue 03.11.08
Table of Contents
IT 1002 Order No BA 93-66-1206 Issue 03.11.08 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 IT 1002 Order No BA 93-66-1206 Issue 03.11.08
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
IT 1002 Order No BA 93-66-1206 Issue 03.11.08 11
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 IT 1002 Order No BA 93-66-1206 Issue 03.11.08
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 A 12, A 16, AI 06, CA 08, PAH-1 and the welding head KAH 412 can
be connected to the HBS power unit IT 1002. 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
IT 1002 Order No BA 93-66-1206 Issue 03.11.08 13
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 IT 1002 Order No BA 93-66-1206 Issue 03.11.08
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
IT 1002 Order No BA 93-66-1206 Issue 03.11.08 15
2 Delivery
The basic equipment of your power unit contains the following components:
No. of pieces Part Type Order No.
1 Power unit IT 1002 93-66-1206
1 Operating Manual IT 1002 BA 93-66-1206
2 Delivery
16 IT 1002 Order No BA 93-66-1206 Issue 03.11.08
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 circulati-
on, the stud welding unit will be seriously damaged.
3 Starting-up
3.1 Requirements of Workplace
IT 1002 Order No BA 93-66-1206 Issue 03.11.08 17
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 IT 1002 Order No BA 93-66-1206 Issue 03.11.08
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
IT 1002 Order No BA 93-66-1206 Issue 03.11.08 19
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 IT 1002 Order No BA 93-66-1206 Issue 03.11.08
3.5 Shielding Gas Connection
Observe the standards (see appendix) when handling the
shielding gas bottles.
Connect the shielding gas bottle as follows:
Connect the gas hose of the shielding gas bottle to the gas inlet of the power
unit.
Connect the gas hose of the welding gun to the gas outlet.
Set the flow meter of the shielding gas bottle to 8 - 16 liters/min.
Minimum flow rate for stud welding with shielded gas is 8 l/min.
A gas mixture of 82% Argon (Ar) and 18% carbon dioxide (CO2) is mainly used for stud
welding.
3 Starting-up
3.5 Shielding Gas Connection
IT 1002 Order No BA 93-66-1206 Issue 03.11.08 21
3.6 Compressed Air Connection for Automatic Stud Feeding
If you use the automatic stud feeder, plug the air hose into the compressed air
supply (6 bar, 800 l/min) of the feeding unit VBZ-3.
Connect the compressed air outlet of the feeding unit to the compressed air inlet
of the power unit.
You can set the operating pressure of max. 6 bars with the
pressure reducing valve of the feeding unit. In the filter unit,
the compressed air is cleaned and drained.
You must not put the air hose into the gas valve of the power
unit! The valve would be destroyed.
3.7 Change Working Place
Switch off the power unit. In this way, you avoid any risk of
electrical shock.
When you move your workplace, disconnect the welding gun and the ground
cables from the power unit. Proceed in reversed sequence as described in
sections 3.2, 3.3, 3.4, 3.5 and 3.6.
After changing the workplace, check the welding gun and the ground cables for
possible damage or missing components.
3 Starting-up
3.6 Compressed Air Connection for Automatic Stud Feeding
22 IT 1002 Order No BA 93-66-1206 Issue 03.11.08
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
4.1.1 Power Unit
The power unit consists of the main assemblies
1 - Mains switch 6 - Control unit
2 - EMC-filter 7 - IGBT switch
3 - Bridge rectifier 8 - Middle-frequency transformer
with diodes
4 - Electrolytic capacitors 9 - Welding current stabilizer
5 - Control unit
After passing the mains switch (1) and the EMC-filter (2), the mains alternating current
is converted in the bridge rectifier (3).
The rectified voltage is smoothed by the electrolytic capacitors (4) and transferred to the
IGBT switches (7). These switches convert the direct current into a high-frequency
alternating current of 30 kHz.
The energy is transferred via the middle-frequency transformer with diodes (8) and
rectified.
The stabilizer (9) smoothes the current and passes it on to the welding sleeves.
Control of the IGBT switches (7) is carried out by the control unit (6).
4 Function
4.1 Components of the Power Unit
IT 1002 Order No BA 93-66-1206 Issue 03.11.08 23
4.1.2 Control Unit
The control unit synchronizes the mechanical sequence (lifting the welding element)
with the electronic control (ignition of pilot arc, ignition of main arc, sequence of welding
time). The welding time is stepless adjustable.
4.2 Keyboard and Display
How to use displays and keys is described in section 5.6.
4 Function
4.2 Keyboard and Display
24 IT 1002 Order No BA 93-66-1206 Issue 03.11.08
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
IT 1002 Order No BA 93-66-1206 Issue 03.11.08 25
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
26 IT 1002 Order No BA 93-66-1206 Issue 03.11.08
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
IT 1002 Order No BA 93-66-1206 Issue 03.11.08 27
5.2 Functional Principle of Stud Welding
The face of a stud-shaped welding element and the opposite surface of the workpiece
are molten by an arc. Stud welding is suitable for the welding of joining elements across
the entire cross-section, mainly using pin-shaped metallic welding elements with
metallic workpieces.
The various processes of arc stud welding are distinguished by:
– The method of weld pool protection (shielding gas - SG, ceramic ferrule - CF or no
protection - NP)
– The length of welding time (standard ARC or short-cycle drawn-arc stud welding - SC)
– The energy source (welding rectifier supplied by mains, inverter, capacitor battery)
Variations for drawn-arc ignition are described in current standards and regulations (see
appendix).
Drawn-Arc Stud Welding
The HBS stud welding unit operates by process of ‘arc stud welding with drawn-arc
ignition’ according to the current standards (see appendix). The standards assign this
method of joining pin-shaped elements with plane workpieces to the so called ‘Arc
Pressure Welding’ (code BH).
Joining is carried out in plastic or liquefied condition of the welding zone. The process
can be carried out mechanically or automatically, depending on the used welding guns/
welding heads.
Generally, the positive pole of the power unit is connected to the workpiece. The welding
element is manually or automatically inserted into the chuck of the welding gun or of the
welding head. Then it is placed onto the workpiece - possibly equipped with a ceramic
ferrule (see position 1). When the button of the welding gun is triggered, the automated
welding process starts, which works as follows:
Pre-flow of shielding gas depending on set pre-flow time (only with shielding gas for weld
pool protection).
5 Stud Welding Procedure
5.2 Functional Principle of Stud Welding
28 IT 1002 Order No BA 93-66-1206 Issue 03.11.08
– At the beginning of the welding process, the welding element (stud) in the welding
gun is lifted clear off the workpiece by a lifting device (solenoid). An initial switched
current triggers a pilot arc of a low current power (see position 2). Then the main arc
ignites between the face area of the welding element and the workpiece.
– The main arc burns at the set current during the welding time preselected at the
power unit. The selected welding energy must match the requirements of the
selected welding element. The energy of the arc melts the face of the welding element
and the workpiece (see position 3).
– At the end of the preset welding time, the stud is mechanically moved to the
workpiece. On plunging into the weld pool, the two weld zones join and solidify. The
contact of stud and workpiece extinguishes the arc in a short-circuit and the main
current is switched off.
– The weld zone solidifies and cools down. The welding element is now welded to the
workpiece over its entire cross-section of the welding element (see position 4). As
soon as the weld metal is cooled down, the welding gun can be carefully withdrawn
from the welding element. When using shielding gas, the shielding gas flow is
switched off with the withdrawal of the welding gun. If a ceramic ferrule is used, it can
be removed by light hammer blows.
The welding range of drawn-arc stud welding is about 3 to 25 mm diameter when using
mild steel/stainless steel. Welding elements with rectangular cross-section should not
exceed a ratio length : width of about 5 : 1. All technical information and adjustment
values are based on the use of welding elements which correspond with current
standards (see appendix).
Variants of drawn-arc stud welding
Item Drawn- arc st u d welding wi th
ceramic ferru le/ring
Drawn- arc stud welding with
shielding gas
Short-cycle stud welding
with shielding g as
Capacitor-d ischarge stu d
welding w ith drawn-arc
Diameter
welding element d
[metric mm (imperial)]
3 - 25
(#4 or 12 gage to 1")
3 - 12 (16)
(#4 or 12 gage to 1/2" (5/8")
3 - 12
(#4 or 12 gage to 1/2")
2 - 8
(14 gage to 5/16")
Max. current I [A] 3000 2500 1500 5000
Welding tim e t [ms ] 50 - 2000 50 - 2000 5 - 100 3 - 10
Energy s ource Welding rectifier
Welding trans form er
Welding rectifier
Welding trans form er
Welding rectifier Capacitor
Weld pool protection Ceramic ferrule CF Shielding gas SG Shielding gas SG
No protection NP
No protection NP
Material welding
element
S 235
CrNi steel
Aluminum (up to 12 mm/0,47")
S 235
CrNi steel
Aluminum (up to 12 m m/0,47")
S 235
CrNi steel
Brass (with shielding gas)
S 235
CrNi steel
Aluminum, brass, copper
Workpiece surface Metallic bright
(rolling skin, rus t film)
Metallic bright
(rolling skin, rus t film)
Metallic bright,
galvanized, light oiled
Metallic bright,
galvanized, light oiled
Min. thickness of
workpiece
¼ d
min. 1 mm (0,04")
1/8 d
min. 1 mm (0,04")
1/8 d
min. 0,6 mm (0,02")
1/10 d
min. 0,6 mm (0,02")
Adjustable parameters Welding current
I [A] = 80 x d
(up to 16 mm/0,63")
Weldi ng current
I [A] = 80 x d
(up to 16 mm/0,63")
Welding current
I [A] = 100 x d
(up to 12 mm/0,47")
Charging voltage
Welding time
t [ms] = 20 x d
(up to 12 mm/0,47")
Weldi ng time
t [ms] = 20 x d
(up to 12 mm/0,47")
Welding ti me Ignition point / lift
Lift
(arc length)
Lift
(arc length)
Lift
(arc length)
Spring pressure
(plunging speed)
Plunging depth Plunging depth Plunging depth Plunging depth
5 Stud Welding Procedure
5.2 Functional Principle of Stud Welding
IT 1002 Order No BA 93-66-1206 Issue 03.11.08 29
5.2.1 Drawn-Arc stud Welding with Ceramic Ferrule
Drawn-arc stud welding with ceramic ferrule is used with welding elements of 3 to 25 mm
diameter (preferably above 12 mm diameter) and with welding times of 50 to 2000 ms.
It is generally suitable for all welding positions. When stud welding with ceramic ferrule,
the welding position is PA (vertical). The major part of all applications applies to this
procedure.
The ceramic ferrule (CF)
– prevents atmosphere from getting to the weld pool by a formation of metal vapor in
the arc chamber
– stabilizes and concentrates the arc, thus decreasing the arc blow effect
– forms the melt under pressure to a weld collar and supports the weld pool on a vertical
wall and overhead
– protects the welder from arc radiation and welding spatters.
Normally, the ceramic ferrule is used for only one weld and is removed after solidification
of the weld pool.
Standard welding elements and ceramic ferrules are described in several standards (see
appendix). When using concrete anchors or shear connectors the front area can be
plane constructed with a small pressed-in aluminum ball.
Studs with cone-shaped front area and aluminum ball are preferably used with
ceramic ferrule.
5 Stud Welding Procedure
5.2 Functional Principle of Stud Welding
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