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KAH 412 LA Automatic Welding Head 94-37-412 Operating Manual...
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+49 (0) 8131 511-100 E-mail post@hbs-info.com www.hbs-info.com KAH 412 LA Operating Manual, Issue 10/2008 Order No. BA 94-37-412 Copyright: The information contained herein may not be copied, reproduced, adapted, merged, translated or used without the prior written consent of the copyright owner.
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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.
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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. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Drawn-Arc Stud Welding with Shielding Gas ............33 5.2.5 Short-Cycle Drawn-Arc Stud Welding with Shielding Gas ........34 5.2.6 Drawn-Arc Capacitor-Discharge Stud Welding ............34 Welding Preparation ................... 35 High-strength Welds................... 35 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Spare Parts ....................57 Accessories ....................64 Manual and Automatic Equipment Parts............. 70 8.4.1 Manual Equipment Part..................70 8.4.2 Automatic Equipment Part ..................71 Dimensional Drawing ................. 72 Environmentally Admissible Disposal ............73 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Further Instructions - Arc Stud Welding ........78 Guarantee Clauses ................ 79 EU-Statement of Conformity ............80 Confirmation .................. 81 Feedback ..................82 Service & Support ................. 83 Index ....................84 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Owners and operators make sure that the welding head 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. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
(place of operation see section 8.1). The welding head KAH 412 can be connected to the HBS power unit ARC 500 Automa- tic, ARC 800 Automatic, ARC 1550 Automatic, IT 90 Automatic, IT 1001 Automatic, IT1002 Automatic, CDM 1601 Automatic, CDM 2401 Automatic, CDM 3201 Automatic and SCD 3201 Automatic.
Accompanying Documents In addition to this operating manual, you must observe the operating manual of the power unit as well as applicable accident prevention and safety instructions. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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: KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
The basic equipment of your welding head contains the following components: No. of pieces Part Type Order No. Welding head KAH 412 LA 94-37-412 equipped for one stud dimension Operating manual KAH 412 LA BA 94-37-412 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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The power unit controls the air between booth bushings. Air connection B (blue marking) and air connection A (black marking) must not be interchanged (ends up in failure during feeding and welding). KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Proceed in reversed sequence as described in section 3.2 and 3.3. After changing the workplace, check the welding head and the ground cables for possible damage or missing components. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Attaching the welding head KAH 412 in Z-direction is done with the quick-change prism system, which is mounted on the backside. The fixture is performed pneumatically or motor-driven, depending on customer’s needs. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
The upper side of the flange must be level with the surface of work piece. Projection of the welding element selection: length stop one step below standard e.g. length of the welding element 12 > length stop 10 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Socket wrench SW17 80-40-085 Pin 2 mm 80-10-208 Chuck * Guide bushing * Pin stop * Plunger * Feeding tube * * Choice according to type and dimension of the welding element KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Now you may plug-in the air connector blue again. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
steps of 0.1 mm. Total piston stroke is 7 mm. If the plunging depth is 2 mm, you can lift max 5 mm. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Remove welding spatters from chuck and slot piston. After you finished the adjustments, put on the rear cap again. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Remove any electrically conductive or electromagnetically sensitive parts from your body before you start welding. In this way, you avoid the risk of electric shock and influence of electromagnetic fields. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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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. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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HBS. In case of any accidents whatsoever, advise a physician, your supervisor, and the official bodies immediately. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
– The use of contact welding for rapidly oxidizing materials like aluminum and aluminum alloys is limited, as the arcing period with contact welding is longer than with gap stud welding. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
5.2.3 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’...
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[m s] = 20 x d (up to 12 mm /0,47") (up to 12 mm/0,47") Lift Lift Lift Spring pressure (arc length) (arc length) (arc length) (plunging speed) Plunging depth Plunging depth Plunging depth Plunging depth KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
With shielding gas, you should only weld in position PA (verti- cal) because due to gravity, the shielding gas cannot prevent flow of the molten metal. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
As a result, welding currents are very high and welding times (< 10 ms) very short. Normally, a weld pool protection is not required. The process is mainly used for welding elements in a diameter range of up to 8 mm. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
– 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). KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
standards and DVS guidelines (see appendix). Before you use another lot of welding elements, carry out some trial welds to verify the parameter setting. In case of disregard you will obtain bad welding results. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
7,1 mm, M5 5/16" 5/16-18 power unit with higher capacity recommended to be checked by trials Welding parameters may differ from rated values if another ground cable configu- ration is used. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Further notes on – welding elements – prestress at installation (tie load) and torque – material combinations see appendix and operating manual of the according welding gun. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
You can check the quality of the weld by means of a visual inspection and a bending test. See also actual standards in the appendix “Arc stud welding of metallic materials“, in section irregularities and corrective actions. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
- Unsym m etric ground c onnection connec tion W eld pool c am e out on one side - W elding gun put at an angle - P ut welding gun vertically to the work piece KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
5.7.2 Bending Test You can purchase from HBS a bending device with inserts for various diameters of the welding elements. The bending test serves as an easy work sample and as a check for the selected welding parameters. The welded joint is stressed by bending in a non-defined way.
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- Pressure too high - Reduce pressure - Contact stud welding - Use gap stud welding instead of not suitable contact stud welding - Workpiece too thin - Adapt thickness of workpiece KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
fitting of compensation masses, or by rotating the welding gun around its vertical axis (applies for welding guns with external welding cable). Arc blow effects and some corrective actions (according to standards, see appendix) Cause Corre ctive action KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
*) Actions marked with *) must only be carried out by qualified electricians! If none of the actions is successful, please contact our service department. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
8 mm 10-40 mm 84-50-008 KAH 412 All elements are available in the base materials S235 / St37.3k (4.8), 1.4301, 1.4303, CuZn37 and AlMg3 ex stock. Other weldable base materials on request. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Protect the welding head against ingress of fluids and foreign bodies. Disposal If you shut down the installation, you can return the complete power unit to HBS (for address see page ii). We will take care of environmentally correct material separation and disposal.
Let maintenance and repair operations be carried out only by qualified personnel or by your competent service technician. Before starting any repair or maintenance operation, always switch the power unit off and disconnect the primary plug. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
There are some markings (type and adjustment guides) placed at the welding head. Take care that markings remain clearly visible. Replace illegible or damaged markings. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
See Position 85, Section 4.3 Operating manual with Amblygon TA 15/2 This maintenance recommendation is regardless of the particu- lar situation in your company. Therefore it is necessary to write down a suitable servicing schedule. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Replace defective and worn equipment components. Pay special attention to any dirt on the parts 102 and 104 and 106. Soiling may cause an interruption of the feeding of welding elements into the chuck. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Detaching the Welding Head Uncouple all supply lines. Make loose the clamp strap (item 67) with the screw M6 x 30 DIN 912 (item 69) and take down the welding head. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Remove the spring admission (item 35). Pull off the air pressure hoses from the swivel connections (item 7). Loosen the threaded pins ( at item 3) and remove the connecting cables. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Remove the swivel connection (item 7 - Attention: Hexagon socket) and the locking pin (item 5) out of the guide piston (item 3) and take them out carefully. Check the guide piston and the linear ball bearings for backlash, wear, dirt. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Clamp the lifting solenoid with the screws (item 27) and check whether the clamping screws are positioned onto the respective sinkings in the lifting soleno- id casing. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Screw on the slot tube holder. Now you may attach the welding head to the machine and equip it with compon- ents which fit to your next application. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
In the appendix, there is information of interest regarding technical data, spare part lists, accessories, standards, etc. Technical Data Automatic Stud Welding Head KAH 412 LA with length compensation for CD or ARC stud welding with automatic stud feeding according to current standards Welding range M3 to M8, dia.
O-ring 44 x 2 80-07-552 Rear cap 88-17-541 Cover plate 80-90-309 Screw M3 x 20 88-17-523 Connection casing, complete 88-11-418 Shock absorber 88-17-035 Cover damper 80-90-107 Screw M3 x 6 80-11-045 Cylindrical pin KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Screw M5 x 6 80-11-087 88-17-056 Sticker, Lift 88-17-532 Type plate 88-17-528 Piston rod, complete 88-17-527 Slot piston, complete 80-07-565 Tension nut 80-07-564 Retaining nut 88-17-524 Support for feeding tube, complete KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Welding head KAH 412 LA (94-37-412) KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Screw M2,5 x 6 80-11-169 Insulating nozzle 88-11-170 Machine cover left side 80-11-530 Connector male 80-11-129 Swivel connection 0.20 m 80-11-176 Plastic hose 88-11-320 Connection casing, complete 80-90-170 Screw M4 x 8 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Connection casing, complete KAH 412 (88-17-523) KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Quantity Order No. Description 88-10-433 Support for feeding tube 80-07-908 Locking pin 80-40-241 Pressure spring 80-07-909 Trigger pin 80-90-133 Screw M3 x 10 80-09-265 Stud bolt 80-90-153 Nut DIN 934 M4 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Spare parts support for feeding tube, complete KAH 412 (88-17-524) KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
When ordering accessories, please specify serial number and type of welding head. The serial number is seen on the name plate. You can order following accessories: Description Order No. ----------------------------------------------------------------------------------------------------- Gas adaptor 80-07-772A Shielding gas tube additionally: 80-08-178A Gas adaptor grounded 80-07-772MA KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Description Order No. ----------------------------------------------------------------------------------------------------- Working stroke complete with ring initiator 80-09-750 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Description Order No. ----------------------------------------------------------------------------------------------------- Working stroke complete without ring initiator 80-09-760 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Description Order No. ----------------------------------------------------------------------------------------------------- Downholder 80-08-702 pneumatic KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Pin 2 mm Plunger Pin stop Feeding tube Chuck Guide bushing KAH 412 Socket wrench 80-40-085 KAH 412 Mounting keys 80-09-281 80-10-208 KAH 412 Standard chuck adaptor 92-40-053 complete KAH 412 Adaptor 80-40-389 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Ø 5 X-mas tree studs 94-43-253B Ø 6 94-43-206B Ø 6 X-mas tree studs 94-43-263B Ø 7,1 94-43-271B Ø 8 94-43-208B Clamp PMB-S PMB-S 80-40-078 Pneumatic ground clamp Clamp PMB-LS PMB-LS 80-40-780 Pneumatic ground clamp KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Environmentally Admissible Disposal After repair of the welding gun, dispose replaced parts in an environmentally admissible way. Used materials: Steel Nonferrous metals (brass, copper) Plastics Aluminum KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
For example: duration and strength of current during welding process, charging voltage, spring force of the welding head. Work piece: A component, like a sheet, tube, etc. to which the welding element is fastened KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
DIN EN 764-1 Pressure equipment - Part 1: Terminology - Pressure, temperature, volume, nominal size DIN EN ISO 6947 Welds - Working positions - Definitions of angles of slope and rotation KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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Safety rules - welding, cutting and similar processes 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. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Exemplificatio n of welding suitability: -- non weldable a well suited fo r any application, e.g. power transmission b suitable, limitatio ns with power transmission Weldability tests of other material combinations on request. weldable KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
-- non w eldable a w ell suited for any application, e.g. pow er transmission b suitable, limitations w ith pow er transmission Weldability tests of other material combinations on request. weldable KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Serial number automatic welding head: ..........Serial number power unit: ..........Serial number welding head: ..........Serial number stud feeder: ..........Please indicate the serial numbers in case of enquiries or when ordering spare parts. KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
DIN EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General requirements valid until 28.12.2009 • Machine guideline 2006/42/EC, valid from 29.12.2009 _______________ ________________________________________ Date Erwin Promoli (General Manager HBS) KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
Felix-Wankel-Strasse 18 __________________________ 85221 Dachau / Germany __________________________ Postfach 13 46 __________________________ 85203 Dachau / Germany __________________________ Product description __________________________ Serial number __________________________ My opinion/criticism/complaints/indication of malfunction: Date and Signature ___________________________________________ KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
........27 clamp PMB-LS ........69 function ..........20 clamp PMB-S ........69 functional principle ....... 10 cleaning agents ........48 further instructions ......77, 78 cleaning operations ......47 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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....... 50 materials, rapidly oxidizing ....29 repair ........... 73 metal spatters ........27 requirements of workplace ....16 mounting keys ........68 retaining nut ........50 retaining nut, loose ......23 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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......51 welding parameters surface of welding element ....41 with drawn-arc ignition ....38 surfaces, workpiece ......41 welding preparation ......35 switching off ........10, 46 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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........... 74 working place, change of ..... 19 working position ........21 working, start ........48 working stroke complete with ring initiator ......65 working stroke complete without ring initiator ...... 66 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08...
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