HBS KAH 412 User manual

©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

2
After-sales service for Germany:
HBS Bolzenschweiss-Systeme GmbH & Co. KG
Felix-Wankel-Strasse 18
85221 DACHAU
GERMANY
Phone [phone]
Fax [phone]
E-mail [email protected]
Web www.hbs-info.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 duplication of this document, dissemination and notication
of the contents are not permitted unless expressly approved.
All rights, errors and technical amendments reserved.
© HBS Bolzenschweiss-Systeme GmbH & Co. KG

3©HBS Bolzenschweiss-Systeme GmbH & Co. KG
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Dear Customer,
Many thanks for buying a stud welding machine from HBS Bolzenschweiss-Syste-
me.
We at HBS wish you success at all times when working with this stud welding ma-
chine.
The high level of quality of our products is guaranteed by ongoing further deve-
lopment in the design, equipment and accessories. This may result in differences
between the present operating manual and 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 every effort to ensure that the information contained in this
manual was correct and up-to-date at the time of delivery. We can nevertheless give
no guarantee for an absolutely error-free document.
Should you discover any errors or unclear points when reading this operating manu-
al, please do not hesitate to contact us.
We would also be grateful for any feedback should you have any suggestions or
complaints to make about our product.
HBS Bolzenschweiss-Systeme GmbH & Co. KG
Felix-Wankel-Strasse 18
85221 Dachau
GERMANY

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4
Table of Contents
Table of Contents
1 Important Safety Precautions ................................................................... 6
2 Symbols and Terms Used ....................................................................... 10
3 Scope of Supply ....................................................................................... 13
4 Accessories .............................................................................................. 13
5 Technical Data .......................................................................................... 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 the Pressure Spring ............................................................................. 24
10.2 Adjusting the Working Position ............................................................................. 25
10.3 Equipping the Welding Head ................................................................................ 28
Manual and Automatic Equipment Parts ............................................................................ 29
10.4 Adjusting Welding Parameters ............................................................................. 35
Adjusting spring force ......................................................................................................... 43
Adjusting the protrusion ..................................................................................................... 44
Adjusting the lift .................................................................................................................. 45
11 Welding ..................................................................................................... 47
12 Troubleshooting ....................................................................................... 48

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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 Display Unit ............................................ 55
14 Storage ..................................................................................................... 57
15 Disposal .................................................................................................... 57
Declaration of Incorporation of partly completed Machinery .......................... 58
Service & Support ................................................................................................ 59
Index ...................................................................................................................... 60

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6
1 Important Safety Precautions
1 Important Safety Precautions
The target group for this manual are qualied personnel who in view of their techni-
cal training, know-how and experience and knowledge of applicable regulations are
able to assess the work assigned to them and recognise potential hazards.
Danger from incorrect use
Use the stud welding machine only for the purpose described in this ma-
nual.
Otherwise you may endanger yourself or damage the stud welding 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 material damage.
Danger for unauthorised operating personnel
Work with the stud welding machine only when
– You are appropriately trained, instructed and authorised to do so, and
– You have read and completely understood this operating manual.
Never work with the stud welding machine when you are under the inu-
ence of
– Alcohol,
– Drugs or
– Medication.
Danger from unauthorised modications
Never modify the stud welding machine or parts thereof without obtaining
a clearance certicate from the manufacturer.
You will otherwise endanger yourself. This can lead to serious injury or ex-
tensive material damage.

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1 Important Safety Precautions
Life-threatening danger for wearers of active implanted cardiac
devices
Danger for workers at particular risk within the meaning of the
EMF directive
Persons at particular risk within the meaning of the EMF directive are:
– Workers with active implanted medical devices
– Workers with passive implanted medical devices that contain metal
– Workers with medical devices worn on the body
– Pregnant workers.
Never operate the stud welding machine if you are among the group
of workers at particular risk 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 are among the group of workers at particular risk within
the meaning of the EMF directive.
Strong electromagnetic elds are produced in the vicinity of the stud
welding machine during welding. These elds can adversely affect the
function of medical devices as well as the course of a pregnancy.
Danger from fumes and airborne particulates
Switch on the welding fume extractor at the place of work.
Ensure that the room is well ventilated.
Never weld in rooms with a ceiling height of less than 3 m.
Observe furthermore your working instructions and the accident
prevention regulations.
This will help to avoid health damage due to fumes and airborne parti-
culates.

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1 Important Safety Precautions
Danger from glowing metal spatter (re hazard)
Glowing hot weld spatter and liquid splashes, ashes of light and a
loud bang > 90 dB (A) must be anticipated during stud welding.
Inform colleagues working in the immediate vicinity accordingly
before starting work.
Ensure that an approved re extinguisher is available at the work-
place.
Do not weld when wearing working clothes soiled with ammable
substances such as oil, grease, petroleum, etc.
Wear your proper protective clothing, such as:
– Protective gloves in accordance with the relevant standard,
– Non-ammable 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 head,
– Safety shoes,
– Safety goggles with sight glass of protection level 2 in compli-
ance with the applicable standards and do not look directly into
the electric arc.
Remove all ammable materials and liquids from the vicinity of the
work area before starting welding.
Weld at a safe distance from ammable materials or liquids.
Select a safety distance large enough to ensure that no danger can
arise from weld spatter.
Protection of the stud welding unit
Protect the stud welding machine against the ingress of foreign
matter and liquids caused by cutting or grinding work in the vicinity
of your work area.
This will help to prolong the service life of your stud welding machine.

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1 Important Safety Precautions
Safety notices in accordance with EMF directive 2013/35/EU
Currents owing through electrical conductors during stud welding cause electric
and magnetic elds that can occur, in particular, near the hand-held welding guns,
the welding arrangement (e.g., welding cables) and the welding power sources.
Due to the high currents, high EMF exposures may occur.
Danger for workers at particular risk within the meaning of the
EMF directive
Persons at particular risk within the meaning of the EMF directive are:
– Workers with active implanted medical devices
– Workers with passive implanted medical devices that contain metal
– Workers with medical devices worn on the body
– Pregnant workers.
Strong electromagnetic elds are produced in the vicinity of the stud
welding machine during welding.
To reduce the danger posed by electromagnetic elds, we recommend, among other
things, the following rules of conduct:
Lay all cables as close together as possible.
For proper bundling and safeguarding of the cables, HBS offers protective tubes in
various sizes.
Do not position yourself between the welding cables.
Only lay the cables to one side and position them as far as possible from the
operating personnel.
Do not loop the cables over your body, especially not at head level.
Completely unwind the welding cables.
Use the shortest possible welding cables.
Place portable welding power sources as far away as possible while welding.
If possible, do not operate welding power sources in the immediate vicinity of
other persons, do not sit directly next to the welding power source while working
and do not lean against it.
In addition to these safety notices, also observe your work instructions and acci-
dent prevention regulations.

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10
2 Symbols and Terms Used
2 Symbols and Terms Used
The symbols used in this operating manual have the following meanings:
Danger
Warns you of hazards that can lead to injury of persons or to
considerable material 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 access for pregnant women
Danger
Warns you of electrical hazards
Danger
Warns you of electromagnetic elds that can be generated during welding
These symbols prompt you to wear personal protective clothing when
working with the stud welding unit.
This symbol prompts you to wear ear protection. A loud bang > 90 dB (A)
can occur during the welding process.

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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 in italics
Fire hazard
Have a suitable re extinguisher for the working area ready before starting
work.
Work instruction
– List

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12
2 Symbols and Terms Used
Glossary
Automatic welding head: Device for welding of welding elements
Capacitor: Component for storage of electrical energy.
Electric arc: Autonomous gas discharge between two electro-
des when the current is high enough. A whitish light
is emitted in the process. The electric arc allows
very high temperatures to be generated.
Rectier: Electrical component that converts alternating vol-
tage into 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 or
welding head
Stud welding unit: Device for provision of the electrical energy for
stud welding
Thyristor: Electronic component for contact-free switching of
high currents; switching takes place via the control
input
Welding element: Component such as stud or pin that is welded to
the workpiece
Welding parameters: Mechanical and electrical settings at the stud wel-
ding gun or welding head and at the stud welding
unit (e.g. spring force, charging voltage)
Workpiece: Components such as sheet metal or tubes to which
the welding elements are to be fastened

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3 Scope of Supply
3 Scope of Supply
The basic conguration of your welding head unit contains the following parts:
No. of
pieces
Part Type Order No.
1 Automatic welding head KAH 412 94-31-412C
equipped for one stud dimension
1 Operating manual KAH 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 or the dealer (address, see page 2).
4 Accessories
For example:
Mounting tool set 80-09-281
Pressure spring for converting to contact welding method 80-40-695
Special equipment for increasing the immersion depth to + 210 mm
such as for welding elements M8 x 20 88-22-391
for welding elements M6 x 15 88-22-391615
Additional accessories can be found in our extensive accessories catalogue.

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14
5 Technical Data
5 Technical Data
Automatic Stud Welding Head Type KAH 412
with Digital Display for CD or ARC stud welding with automatic stud feeding
according to current standard
Welding range M3 to M8, dia. 3 to 8 mm
(dia. 10/12/12.7 mm with modication only)
Stud length 8 to 40 mm (standard - other lengths
on request)
Stud material Mild steel, stainless steel, aluminium, brass
Lift Adjustment range 5 mm, arresting
Spring force Arresting
IP Code IP 20 (protect against humidity)
Workplace noise level > 90 dB (A) may occur during welding
Ambient temperature limits 0 °C to 40 °C
Dimension L x W x H 375 x 66 x 145 mm
(with chuck and quick change system)
Weight 3.4 kg

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5 Technical Data
Dimensional drawing welding head KAH 412

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5 Technical Data
Downholder pneumatic (Order No. 80-08-702)

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6 Intended Use
6 Intended Use
The welding head has been designed exclusively for 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 welding units.
Always check with the operating manual of your stud welding unit whether this
welding head may be used.
Observation of the operating manual of the used stud welding unit is also part of the
intended use.

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7 Warranty
7 Warranty
Please refer to the latest "General Terms and Conditions" for the scope of the
warranty.
The warranty does not cover faults caused by e.g.
– Normal wear,
– Improper handling,
– Failure to observe the operating manual,
– Failure to observe the safety precautions,
– Use for other than the intended purpose, or
– Transport damage.
Warranty entitlement shall no longer be valid if modications, changes or service
and repair work is carried out by unauthorised persons or without the knowledge of
the manufacturer. Invalidation of warranty entitlement shall also render the declara-
tion of conformity invalid. The CE marking shall be declared invalid by the manufac-
turer.
We expressly point out that only spare parts and accessories or components appro-
ved by us may be used. The same applies likewise to installed units from our sub-
suppliers.

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8 Components of the Automatic Welding Head
8 Components of the Automatic Welding Head
8.1 Main Assemblies
A - Rear cap
B - Spring adjustment screw
C - Display spring adjustment
D - Lift adjustment screw
E - Connection casing
F - Display lift
G - Screw height adjustment
H - Height adjustment
The base body of the KAH 412 automatic welding head consists of a section of
square aluminium.
All supply lines (welding current cable, control cable, compressed air lines) are
plugged into the connection casing (E).
Located on the front of the KAH 412 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 slot piston
with guide sleeve to the chuck. The plunger cylinder integrated in the piston (moun-
ted backlash-free with linear ball bearings) pneumatically moves the welding ele-
ment through the chuck to the welding position.
The entire adjusting mechanism for lift and spring force is located above the connec-
tion casing (E). The lift adjustment can be read via a digital measurement system.
The spring pressure is displayed directly via a scale.
The KAH 412 automatic welding head is secured to the Z-axis (either pneumatically
or by means of a motor) via the prism quick-change system attached to the rear.
The type plate is located on the front of the welding head.

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20
8 Components of the Automatic Welding Head
Type plate
The type plate contains the following information:
– Manufacturer
– Type
– Order No./Serial No.
– Date.