HBS KAH 412 LA Manuel utilisateur

KAH 412 LA

Automatic Welding Head

94-37-412

Operating Manual

ii KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08

KAH 412 LA Operating Manual, Issue 10/2008 Order No. BA 94-37-412

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

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.

iii

KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08 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 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08

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.

KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08 v

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, Storage ........................................................... 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 Welding Head to the Power Unit ....................................... 17

3.3 Ground Connection .................................................................................... 19

3.4 Change Working Place .............................................................................. 19

4 Function ......................................................................................... 20

4.1 Components of the Welding Head ............................................................. 20

4.2 Adjuﬆing the Working Position ................................................................... 21

4.3 Equipping the Welding Head for a Welding Fitting...................................... 22

4.4 Adjuﬆments ............................................................................................... 24

5 Stud Welding Procedure .............................................................. 26

5.1 Safety Inﬆructions ...................................................................................... 26

5.2 Functional Principle of Stud Welding .......................................................... 29

5.2.1 Contact Stud Welding ............................................................................................ 29

5.2.2 Gap Stud Welding .................................................................................................. 30

5.2.3 Drawn-Arc Stud Welding ........................................................................................ 31

5.2.4 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

5.3 Welding Preparation ................................................................................... 35

5.4 High-ﬆrength Welds ................................................................................... 35

vi KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08

5.5 Determination of Welding Parameters ....................................................... 36

5.5.1 Standard Welding Parameters for Tip Ignition with Gap .......................................... 37

5.5.2 Standard Welding Parameters for Gap Stud Welding with

Drawn-Arc Ignition under Shielding Gas ................................................................. 38

5.6 Welding Procedure .................................................................................... 39

5.7 Checking the Quality of the Weld ............................................................... 39

5.7.1 Visual Inspection ................................................................................................... 40

5.7.2 Bending Test .......................................................................................................... 41

5.7.3 Arc Blow Eﬀect ...................................................................................................... 43

5.8 Possible Malfunctions and Corrective Actions ............................................ 44

5.9 Welding Elements ...................................................................................... 45

6 Switching oﬀ the Power Unit ........................................................ 46

6.1 Temporary Switching off ............................................................................. 46

6.2 Disposal ..................................................................................................... 46

7 Care and Maintenance .................................................................. 47

7.1 Safety Inﬆructions ...................................................................................... 47

7.2 Regular Maintenance Operations ............................................................... 48

7.3 Maintenance and Cleaning the Welding Head ............................................ 49

7.4 Removing the Equipment ........................................................................... 50

7.5 Detaching the Welding Head ...................................................................... 51

7.6 Dismounting and Cleaning the Welding Head ............................................ 52

7.7 Assembling the Welding Head ................................................................... 54

8 Appendix ........................................................................................ 56

8.1 Technical Data ............................................................................................ 56

8.2 Spare Parts ................................................................................................ 57

8.3 Accessories ............................................................................................... 64

8.4 Manual and Automatic Equipment Parts..................................................... 70

8.4.1 Manual Equipment Part.......................................................................................... 70

8.4.2 Automatic Equipment Part ..................................................................................... 71

8.5 Dimensional Drawing ................................................................................. 72

8.6 Environmentally Admissible Disposal ......................................................... 73

KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08 vii

Glossary ......................................................................................... 74

Regulations and Standards .......................................................... 75

Further Inﬆructions - Tip Ignition ................................................. 77

Further Inﬆructions - Arc Stud Welding ...................................... 78

Guarantee Clauses ........................................................................ 79

EU-Statement of Conformity ......................................................... 80

Conﬁrmation .................................................................................. 81

Feedback ........................................................................................ 82

Service & Support ......................................................................... 83

Index ............................................................................................... 84

viii KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08

KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08 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 welding

head.

Required user qualiﬁcation

The welding head muﬆ only be operated by qualiﬁed personnel.

Let the welding head 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 welding head.

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.

Protect the welding head 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 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.

10 KAH 412 LA Order No. BA 94-37-412 Issue 23.10.08

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" 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 welding head. 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.

Ce manuel convient aux modèles suivants

Table des matières

Manuels Système de soudage populaires d'autres marques

Berner

Berner PLASMACUT 54 Manuel utilisateur

Pro Spot

Pro Spot PR-155 Manuel utilisateur

Forney

Forney 210 Manuel utilisateur

Thermal Arc

Thermal Arc 400S Manuel utilisateur

Lincoln Electric

Lincoln Electric HANDYMIG 170I Manuel utilisateur

GYS

GYS PROTIG 201 AC/DC Manuel utilisateur

TAFA

TAFA 30*8B35 Manuel utilisateur

Lincoln Electric

Lincoln Electric INVERTEC V350-PRO CE Manuel utilisateur

ESAB

ESAB Buddy Arc 145 Manuel utilisateur

CIGWELD

CIGWELD 636804 Guide rapide

Red-D-Arc

Red-D-Arc DC-400 Manuel utilisateur

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 Manuel utilisateur

Elettro

Elettro HI-MIG 3000 SYNERGIC Manuel utilisateur

WIA

WIA Weldmatic 270 CP132-2 Manuel utilisateur

Sonics

Sonics H520T Manuel utilisateur

Miller

Miller Big Blue 400D Manuel utilisateur

NewArc

NewArc RT2000 Guide de démarrage rapide

Hypertherm

Hypertherm powermax1000 Manuel utilisateur