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©HBS Bolzenschweiss-Systeme GmbH & Co. KG

All rights reserved – Reprinting, in whole or in part, only with the approval of the manufacturer

10 Preparing the Welding Head

Determining the protrusion - drawn arc

The following setting values are recommended for drawn arc welding of stud types 

PD, UD, ID:

Stud-Ø in mm

Protrusion in mm

5

2.5

6

3.0

7

3.2

8

3.5

10

4.0

12

4.4

Stud welding drawn-arc ignition

Workpiece

Protrusion of the welding element 

Select pin stop one level shorter than standard 

e.g. length of the welding element 12 > 

pin stop 10

Summary of Contents for 94-31-412C

Page 1: ...HBS Bolzenschweiss Systeme GmbH Co KG All rights reserved full or partial reproduction subject to prior approval of the manufacturer Operating Manual KAH 412 Automatic Welding Head 94 31 412C 2021...

Page 2: ...nfo com KAH 412 Operating Manual Issue 2021 01 Order No E BA 94 31 412C Translation of the Original Operating Manual Please keep the manual in a safe place for future reference Transmission and duplic...

Page 3: ...your product No claims can therefore be derived from the data illustrations and descriptions We have compiled the data and information in this reference work with the greatest care and have made ever...

Page 4: ...14 6 Intended Use 17 7 Warranty 18 8 Components of the Automatic Welding Head 19 8 1 Main Assemblies 19 8 2 Keyboard and Display 21 9 Welding Process 22 10 Preparing the Welding Head 23 10 1 Replacing...

Page 5: ...Table of Contents 13 Maintenance and Care 50 13 1 Cleaning 50 13 2 Inspection and Tests 52 13 3 Removing Equipment 53 13 4 Dismounting the Welding Head 54 13 5 Changing the Battery for the Electronic...

Page 6: ...ding machine You endanger yourself and others if you operate the stud welding machine incorrectly or fail to observe the safety precautions and warnings This can lead to serious injury or extensive ma...

Page 7: ...within the meaning of the EMF directive In this case never remain in the vicinity of the stud welding machine during welding Never operate the stud welding machine if persons are located nearby who ar...

Page 8: ...ce with the relevant standard Non flammable clothing A protective apron over your clothing Full ear hearing protection in accordance with the relevant stan dard A safety helmet when welding above your...

Page 9: ...orkers Strong electromagnetic fields are produced in the vicinity of the stud welding machine during welding To reduce the danger posed by electromagnetic fields we recommend among other things the fo...

Page 10: ...damage Caution Problems in operating may occur if this information is not observed No access for people with active implanted cardiac devices No access for persons with implants made of metal No acce...

Page 11: ...facturer 2 Symbols and Terms Used Tip Cross reference to useful information on the use of the stud welding machine Cross references in this operating manual are marked with this symbol or are printed...

Page 12: ...nto direct voltage Stud feeder Device for automatic feeding of welding elements Stud welding gun Device for welding of welding elements Stud welding system Stud welding unit including stud welding gun...

Page 13: ...H 412 E BA 94 31 412C Inspect the shipment for visible damage and completeness immediately on re ceipt Report any transport damage or missing components immediately to the delive ring shipping agent o...

Page 14: ...ng to current standard Welding range M3 to M8 dia 3 to 8 mm dia 10 12 12 7 mm with modification only Stud length 8 to 40 mm standard other lengths on request Stud material Mild steel stainless steel a...

Page 15: ...15 HBS Bolzenschweiss Systeme GmbH Co KG All rights reserved Reprinting in whole or in part only with the approval of the manufacturer 5 Technical Data Dimensional drawing welding head KAH 412...

Page 16: ...HBS Bolzenschweiss Systeme GmbH Co KG All rights reserved Reprinting in whole or in part only with the approval of the manufacturer 16 5 Technical Data Downholder pneumatic Order No 80 08 702...

Page 17: ...use with standardised stud welding elements The use of any other elements will result in the desired strength of the welded joint being diminished This welding head must only be connected to HBS stud...

Page 18: ...afety precautions Use for other than the intended purpose or Transport damage Warranty entitlement shall no longer be valid if modifications changes or service and repair work is carried out by unauth...

Page 19: ...2 automatic welding head is the feed tube which can be quickly changed via the pushbutton locking system The infeed manual or automatic of the welding elements takes place via the feed tube in the slo...

Page 20: ...l rights reserved Reprinting in whole or in part only with the approval of the manufacturer 20 8 Components of the Automatic Welding Head Type plate The type plate contains the following information M...

Page 21: ...nd Display 1 2 Pushbutton 0 ON Pushbutton mm inch Operating the electronic display unit To switch on briefly press the 0 ON pushbutton or move the guide piston To switch off press the 0 ON pushbutton...

Page 22: ...turer 22 9 Welding Process 9 Welding Process This welding head is designed to be used for the following welding processes Capacitor discharge gap welding Drawn arc short cycle stud welding drawn arc w...

Page 23: ...he Welding Head 10 Preparing the Welding Head Prepare the welding head by adjusting the working position preparing the welding head for a welding element and adjusting lift and spring force Do not con...

Page 24: ...the following 1 Rear cap 2 Spring adjustment screw 6 Pressure spring 7 Pointer 8 Cylindrical pin 9 Lift adjustment screw Pull off the rear cap 1 Release the spring adjustment screw 2 with a 17 mm sock...

Page 25: ...stment screw clockwise to the stop block 2 Move the Z axis in setup mode to the working position until a contact signal is displayed on the stud welding unit To manually set the insertion depth on the...

Page 26: ...ss used stud diameter shape of the spatter ring or the welding seam the protrusion can vary between 0 7 mm and 2 mm Gap welding tip ignition Workpiece Protrusion of the welding element 1 5 mm The uppe...

Page 27: ...Determining the protrusion drawn arc The following setting values are recommended for drawn arc welding of stud types PD UD ID Stud in mm Protrusion in mm 5 2 5 6 3 0 7 3 2 8 3 5 10 4 0 12 4 4 Stud we...

Page 28: ...Air outlet blue 5 Compressed air supply Included in the delivery contents of the automatic welding head is a set of equipment of your choice consisting of 14 13 12 11 10 9 15 8 16 7 6 Pos No Descript...

Page 29: ...10 3 84 50 003 5 5 4 x 8 84 40 531 2 5 80 07 782 40 80 07 762 6 3 80 07 802 6 3 84 50 004 6 5 4 x 10 84 40 531 2 5 80 07 783 42 80 07 762 6 3 80 07 802 6 3 84 50 004 6 5 4 x 12 84 40 531 2 5 80 07 78...

Page 30: ...07 805 10 3 84 50 071 9 5 7 1 x 12 84 40 561 4 6 80 07 784 44 80 07 765 10 3 80 07 805 10 3 84 50 071 9 5 7 1 x 15 84 40 561 4 6 80 07 785 47 80 07 765 10 3 80 07 805 10 3 84 50 071 9 5 7 1 x 20 84 4...

Page 31: ...4 x 8 84 40 531 2 5 80 07 782 40 80 07 762 6 3 80 08 162 6 3 84 50 004 6 5 4 x 10 84 40 531 2 5 80 07 783 42 80 07 762 6 3 80 08 162 6 3 84 50 004 6 5 4 x 12 84 40 531 2 5 80 07 784 44 80 07 762 6 3...

Page 32: ...8 165 10 3 84 50 071 9 5 7 1 x 12 84 40 561 4 6 80 07 784 44 80 07 765 10 3 80 08 165 10 3 84 50 071 9 5 7 1 x 15 84 40 561 4 6 80 07 785 47 80 07 765 10 3 80 08 165 10 3 84 50 071 9 5 7 1 x 20 84 40...

Page 33: ...the piston rod pos 17 to the front end position Any equip ment in the automatic welding head is pressed out Insert the pin pos 15 into the cross hole of the piston rod and use pliers to carefully tig...

Page 34: ...der no 80 07 565 Tightening torque 22 Nm Retaining nut pos 7 order no 80 07 564 Tightening torque 14 Nm A loose retaining nut will damage the chuck the slot piston and the retaining nut Press the trig...

Page 35: ...he Welding Head 10 4 Adjusting Welding Parameters Lift and spring force are dependent on among other things the workpiece and welding elements used and their diameters as well as the welding procedure...

Page 36: ...welding M5 5 mm 5 mm M3 2 0 5 4 8 suitable for welding M6 6 mm 6 mm M4 2 0 5 4 8 suitable for welding M8 7 1 mm 7 1 mm M5 2 0 5 Material of workpiece Galvanised steel suitable for welding 4 8 suitabl...

Page 37: ...e in mm Material of workpiece Mild steel suitable for welding 4 8 suitable for welding M3 3 mm 10 4 8 suitable for welding M4 4 mm 10 4 8 suitable for welding M5 5 mm 5 mm M3 10 4 8 suitable for weldi...

Page 38: ...e Welding Head Stud welding units CDMi 2402 CDMi 3202 SCD 3201 CDi 1502 Autom Material of welding elements Diameter of welding elements Welding parameters metric KAH 412 PT UT IT Spring force in mm Ma...

Page 39: ...n mm Material of workpiece Mild steel suitable for welding 4 8 suitable for welding M3 3 mm 1 0 5 4 8 suitable for welding M4 4 mm 1 0 5 4 8 suitable for welding M5 5 mm 5 mm M3 1 0 5 4 8 suitable for...

Page 40: ...ble for welding M3 3 mm 1 0 5 4 8 suitable for welding M4 4 mm 1 0 5 4 8 suitable for welding M5 5 mm 5 mm M3 1 2 5 4 8 suitable for welding M6 6 mm 6 mm M4 1 4 5 4 8 suitable for welding M8 7 1 mm 7...

Page 41: ...ring force in mm Material of workpiece Mild steel suitable for welding 4 8 suitable for welding M3 3 mm 1 0 5 4 8 suitable for welding M4 4 mm 1 0 5 4 8 suitable for welding M5 5 mm 5 mm M3 1 0 5 4 8...

Page 42: ...turer 42 10 Preparing the Welding Head Detail of lift spring force Detail of casing cover O FF O N I O FF O N A Rear cap B Spring force adjustment screw C Display of spring force D Lift adjustment scr...

Page 43: ...our welding parameters e g spring force 5 mm To do this turn the spring force adjustment screw B with a WAF 17 socket wrench to the value that is to be set The scale makes use of a vernier scale 0 5 o...

Page 44: ...to 0 00 0 00 Move the Z axis in setup mode to the working position The set value appears on the display as a negative value 2 00 Adjust the protrusion according to your welding task e g protrusion 2 5...

Page 45: ...value 3 00 D Now turn the lift adjustment screw D to the value that is to be set The set value appears on the display as a negative value 3 50 Mount the rear cap The lift must be checked following ea...

Page 46: ...ive service life of the battery by switching off the battery indicator after you have prepared the welding head Push the trigger for 0 ON next to the display to the left for approx 2 seconds The displ...

Page 47: ...ual of the HBS stud welding unit Danger if used other than for the intended purpose Use the welding head only for CD stud welding or ARC stud welding and only in combination with stud welding units fr...

Page 48: ...vement Clean or replace Qualified specialists Scorching at welded element Chuck is worn Check chuck for possible wear Replace chuck Trained personnel Automatic welding head does not weld Control cable...

Page 49: ...ce in a technically correct way Connect ground cable Trained personnel Check ground cable for electrical flow In case of no flow Replace ground cable Qualified specialists Stud welding unit defective...

Page 50: ...welding head Repairs may only be carried out by appropriately qualified personnel Inform your dealer or your maintenance department 13 1 Cleaning Clean the casing of your welding head with a slightly...

Page 51: ...ined personnel Chuck x Trained personnel Guide sleeve x Trained personnel Plunger x Trained personnel Feed tube x Trained personnel Pin stop x Trained personnel Feeding tube x Check for kinks Check fe...

Page 52: ...very use inspect the bellows on the front part of the automatic welding head for proper assembly and or damage Never work with damaged or incorrectly seated bellows This will contribute to a long serv...

Page 53: ...stem Unplug the blue air hose on the stud welding unit Unscrew the retaining nut pos 7 with a WAF 17 socket wrench pos 16 Remove the chuck pos 6 Apply a short pulse of air on the blue air hose and the...

Page 54: ...ith the approval of the manufacturer 54 13 Maintenance and Care 13 4 Dismounting the Welding Head Move the welding head to a suitable working posi tion Switch off the CNC system Disconnect all connect...

Page 55: ...illumination of the letter B on the display of the welding head After this occurs only a few hours of use remain To change the battery you need a CR 2032 3 volt battery order no 80 50 955 and an adhes...

Page 56: ...sition of the welding head must be checked and re aligned if necessary For this purpose we recommend using the HBS adjustment set for the wel ding head position Never dispose of used batteries in hous...

Page 57: ...t free location when not in use Protect the welding head from moisture and metallic contamination Store the welding head only under the following ambient conditions Storage temperature 5 C to 50 C Rel...

Page 58: ...5 1 1 5 2 1 5 4 1 5 5 1 5 6 1 5 8 1 5 10 1 5 11 1 5 16 1 6 1 1 6 2 1 6 3 1 6 4 1 7 1 1 1 7 2 1 7 3 1 7 4 that special technical documentation was compiled in accordance with Part B of Annex VII of the...

Page 59: ...r Detailed descriptions of errors Service Support may be done up to the value of EUR without quotation Yes No Could you find any damage burn marks on the cables Yes No on chucks Yes No Are all plug an...

Page 60: ...rvice Support 49 59 full ear hearing protection 8 fumes harmful to health 7 G glossary 12 goggles with visor 8 H hazards for the machine 10 hazards for the operator 10 heart pacemaker 7 10 helmet 8 I...

Page 61: ......

Page 62: ...HBS Bolzenschweiss Systeme GmbH Co KG Felix Wankel Strasse 18 85221 DACHAU GERMANY Phone 49 8131 511 0 Fax 49 8131 511 100 E mail international hbs info com www hbs info com...

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