Vicks Welder PS-0K User's Manual
Contents
1. 1 2 3 4 ecce 5206 0593 012 1 Stud 3 Counternut 2 Stud holder 4 Stop screw If other stud diameters are used different stud holders matching the stud diameters are required Set the stud holder as follows Loosen counternut 3 Insert stud 1 into the stud holder The top edge of the stud flange must project over the front edge of the stud holder by about 1 5 mm NOTE The stud must be inserted until it reaches the stop screw 4 Adjust stop screw 4 in the stud holder by rotating movement until the dimension of 1 5 mm between the top edge ofthe stud flange and the front edge of the stud holder is reached Tighten stop screw 4 with the counternut 3 soyer Setting the Stud Welder Pistol 4 2 Installing the stud holder in the Stud Welding Pistol The following diagram shows how the stud holder is installed in the Stud Welding Pistols PS 1 and PS 3K The Stud Welding Pistols PS OK and PS 1K are equipped with a support tube instead of the pistol feet 1 5205 0693 010 1 Pistol foot 4 Bellows 2 Stud holder 5 Spring shaft 3 Union nut 6 Stud flange Loosen union nut 3 on Stud Welding Pistols PS 1 and PS 3K using the socket spanner SW 17 for Stud Welding Pistols PS OK and PS 1K socket spanner SW 14 is required Push stud holder 2 into the spring shaft 5 until it stops Fix stud holder 2 into position with union2. 8 Studs 02 8 02 10 093 8 03 8mm Field of application 1 2r 2 3 Welding system Tip ignition in accordance with DVS Leaflet 0903 Welding and control cable 3 m highly flexible Weight without cable 0 5 Kg 0 9 kg 0 3 kg 0 4 kg 1 Steel stainless steel aluminium and brass 2 Steel and stainless steel 3 Steel stainless steel and brass soyer Safety instructions 3 Safety instructions These Operating Instructions contain fundamental instructions which have to be observed in installation and or operation These Operating Instructions therefore have to be read by the Operator and the responsible technical personnel prior to assembly and initiation They must furthermore be constantly available at the installation site Not only the general Safety Instructions listed under this main item but also the special safety instructions e g for high temperatures voltages etc stated under other main items have to be observed 3 1 Characterisation of references in the Operating Instructions The safety instructions which may cause damage to persons in the case of non observance are specially characterised with the general danger symbol safety instructions in accordance with DIN 4844 W9 warning of electric voltage with the safety symbol in accordance with DIN 4844 W8 3 11 Safety instructions soyer The word ACHTU
3. Insert control cable plug of the Stud Welding Pistol into the control cable Socket 9 11 and lock with spring clip Observe the connecting instructions in the Operating Instructions for Stud Welders Create ground connection of the Stud Welder Connect Stud Welding Pistol as described in Chapter 5 2 Set Stud Welding Pistol as described in Chapter 4 Connect Stud Welder to power supply Set Stud Welder for the welding studs to be welded Insert welding stud into the stud holder Position Stud Welding Pistol onto the workpiece and press release switch 5 21 soyer Initialisation 5 4 Welding parameters The following charging voltages specified in the diagram below are standard values which have been determined in combination with the respective stud welder and the standard Welding Pistol PS 1 AIMg3 and StVK were used as stud material AIMg3 or St as base material The charging voltages vary from the stated setting according to the material type workpiece thickness and surface condition of the workpiece 5 4 1 Stud Welder BMS 660 90 220 200 180 160 140 120 100 80 60 Charging voltage V M3 4 5 M6 M8 Stud diameter SZ 0011 E 5 4 2 Stud Welder BMS 690 135 220 200 180 160 140 120 100 80 60 Charging voltage V M3 4 5 M6 M8 Stud diameter SZ 0012 E 5
4. Hp NUUR UJ UJ NJ NJ NJ rH soyer Table of Contents Implementation of sample taking Production of samples Visual check Tension test e n AETA NJ NJ NJ NA NO HHP LE soyer Table of Contents 10 11 Perspective presentation of Stud Welding Pistol PS 3K Spare parts list Stud Welding Pistol PS OK Perspective presentation of Stud Welding Pistol 5 0 Spare parts list Stud Welding Pistol PS 1K o9 N Go UW WW WN 4 CO WO CO 9 36 General information 1 General information 1 1 The following should be principally observed With this Stud Welding Pistol you have purchased a product which e e corresponds to the latest state of the art in technology complies fully to the present day safety standards and enables successful operating Please observe the following points in any case before installing the Stud Welding Pistol e Store the Operating Instructions in a place to which every Operator has access Ensure that the respective Operator has read and understood the Operating Instructions before installation Each Operator should sign a written confirmation to certify this Prevent use of Stud Welder by unauthorised personnel An electronics technician should check whether the electric supply is properly protected by fuse
5. Incorrect setting of stud projection to the stud holder Set stud projection to 2 3 mm distance between stud holder and stud weld base Incorrect spring pressure setting Set spring pressure Tilted positioning of welding pistol Ensure that all 3 feet of welding pistol are evenly and simultaneously positioned on the workpiece Standards and List of Directives Warranty Terms soyer 10 Standards and List of Directives DIN 4100 DIN 267 part 5 DIN 17100 DIN 8563 part 10 DIN 32500 part 3 DIN 50049 DIN 50125 DIN 54111 part 1 DVS Leaflet 0902 DVS Directive 0905 part 1 DIN EN 292 2 11 Warranty Terms 10 11 38 Welded steel constructions with primarily dead load Screws nuts and similarparts technicaldelivery terms examination and acceptance General construction steels quality standard Ensuring the quality of welding works Studs for stud welding with retract ignition Certificate on material tests Testing metallic materials tensile samples directives for production Destruction free testing methods Electric arc welding with retract ignition Ensuring the quality of stud welding joints Operating Instructions We warrant for a period of 6 months for these Stud Welding Pistols in accordance with our Sales and Delivery Terms The warranty claim expires if damage is caused by improper operation or if repairs or interferences have been made by unauth
6. Order No P02131 F01151 F01152 F01153 F01154 F01155 F01156 F01375 F01376 F01358 F01620 F01377 F02652 M01797 F01736 F01716 F01730 F01717 1 M01562 M01579 E02103 E02104 F01717 M01998 M01561 M01809 F01728 F01737 F01721 F02990 F01484 F01731 M01333 M01374 F01734 M01333 F01729 M01601 E02349 E01963 F02270 FA E F01715 E02101 M01337 M01387 M01087 M01074 M02108 soyer Spare parts 8 4 Perspective presentation of Stud Welding Pistol PS 3K 206 0993 025 8 31 Spare parts soyer 8 5 Spare parts list for Stud Welding Pistol PS OK 8 32 Item No Quantity Designation WO UJ FA FA n JU HJ QJ H3 F3 F3 F3 H3 Cheese head screw x 20 galvanised __ Support tube Centring plate Union nut galvanised Bellows Cap red Hand actuated auxillary switch Pistol housing imprinted Working piston Pressure spring Insert nut M4 x 6 Insert nut M3 x 6 Complete ground cable Strain relief Antikink coil Complete pistol cable Straight pin 9 3 x 6 Threaded pin M5 x 8 Threaded pin M8 x 8 Cheese head screw x 6 galvanised __ Order No M01311 F01472 M01713 F01471 F01469 F02989 F01418 M01315 E02104 E02103 F02152 M01595 F01419 F01473 F01468 M01809 M01699 F01474 FA F01413 E02349 E02101 F01420 FA E M01775 M01337 M02108 soyer Spare parts 8 6 Perspective presen
7. This closed pistol design guarantees additional stability and solidity advantages in contrast to the semimonocoque design With the modular concept it is possible to retrofit the pistol to other stud welding systems using existing mechanical sets The Stud Welding Pistol PS 3K corresponds to the latest state of the art in technology and fits like a glove similar to all other SOYER Stud Welding Pistols thanks to its excellent ergonomic design g 40 Z06 0593 003 X 2 7 soyer Description ofthe Stud Welder Pistols 2 4 Stud Welding Pistol PS OK 2 8 The SOYER Stud Welding Positioning Pistol PS OK is an innovation and unique on the world market due to its small dimensions It is suitable for contact welding in accordance with the tip ignition welding method for studs and pins of steel and special steel and was developed in particular for stud welding in narrow or hardly accessible spaces or on complicated workpieces Despite its small dimensions perfect welding results are nevertheless achievable with the Stud Welding Pistol PS OK which can be compared with the welding qualities created with larger manual welding pistols This Stud Welding Pistol can be easily connected to all thyristor driven stud welding equipment in accordance with the tip ignition principle 75 Display scale 1 1 5205 0594 014 soyer Description of the Stud Welding Pistols 2 5 Stud Welding P
8. 22 soyer Initialisation 5 4 3 Stud Welder BMS 6H Charging voltage V 5 4 4 Stud Welder BMS 8H Charging voltage V 220 200 180 160 140 120 100 80 60 220 200 180 160 140 120 100 80 60 M4 M5 Stud diameter M8 SZ 0013 E M4 M5 Stud diameter M8 Z 0014 E Quality Control soyer 6 Quality Control 6 1 General information The DVS directive 0905 part 2 of April 1979 is valid with regard to ensuring the quality of stud welded joints The tests described in this section have been written in a simplified form on the basis of this directive They refer to work tests which are carried out and controlled by the User prior to and during welding works Heinz Soyer Bolzenschwei technik GmbH is a member of the Deutscher Verband f r Schwei technik e V DVS German Welding Society Munich 6 2 Demands on the company The company must appoint a responsible welding supervisor and employ appropriately qualified operating personnel for stud welding see DVS Directive 0905 part 2 section 4 6 3 Proof of qualification In the case of components which are subject to documentation requirements and or stud welding works which are subject to acceptance in compliance with DIN 4100 DIN 4113 the manufacturing company must submit proof of competence or a qualification certi
9. Stud Welding Pistol which may get damaged by weld spatters such as stud holder and pistol feet and or centering support tube should however be kept clean The stud holder and pistol feet are wear and tear parts and should be replaced if they display any signs of wear and tear AN MORTAL DANGER Before replacing any components disconnect power supply Electric and electronic components may only be replaced by a specialist if necessary consult SOYER Customer Service 7 2 Replacing components Components may only be replaced by specially trained SOYER service technicians Perfect Stud Welder functions can only be guaranteed if original SOYER spare parts are used AN MORTAL DANGER Before replacing components ensure that the capacitors have been discharged Spare parts soyer 8 Spare parts 8 1 Spare parts list for Stud Welding Pistol PS 1 8 28 Item No Quantity Designation FA EA Fa Ea pa rn pn pm RPP PPP HI Fi rip p IB Hn Hm m mp m H HI IH H NU I Stud Welding Pistol PS 1 comprising Grounding foot Foot ring Union nut Rubber bellows Guide sleeve Straight pin 3 x 8 Working piston Feather key Release ring Pistol shell LHS Pistol shell RHS Trigger handle Straight pin 3 x 18 Straight pin 3 x 30 Pressure spring Release arm Clamping ring Pressure spring Spring guide Set collar Setting screw Locking ring Ground plug Strain reli
10. ignition tip Use stud with ignition tip or reduce centre mark Fault in Stud Welder control and or at the Stud Welding Pistol Inform SOYER Customer Service Stud too loose in stud holder Press stud holder together and or tighten it Stud thread scorched Stud holder worn down Replace stud holder Varying welding results Incorrect welding energy setting Set welding energy Cable connections are too loose transition resistances are generated Check all cable connections and cable clamps to ensure tight fit Stud is too loose and or has not been inserted into the stud holder until the stop is reached Press stud into the holder until it stops if necessary replace stud holder Magnetic blow effect The electric arc is pressed into a certain direction Alter ground clamp attachment place iron parts to the edges and or rotate welding pistol Intensive sparking stud flange almost fully melted away Welding energy setting too high Reset welding energy using the energy range selector Stud not welded with complete flange surface deficient weld joint strength Welding energy setting too low Reset welding energy using the energy range selector Poor ground connection gt Ensure tight fit of ground cable and ground clamps if necessary tighten Workpiece surface too soiled Clean workpiece surface Stud weld base deformed Use new welding studs
11. welding operation Wear a helmet when carrying out welding operations above your head AN DANGER Do not weld with work dress which is soiled with easily combustible substances such as oil grease paraffin oil etc Safety instructions soyer Wear leather gloves with sleeves Wear neither rings watches nor electrically conducting jewellery Wear protective goggles with eye protecting lens of shade number 2 DIN 58211 part 6 Weld spatters and light flashes are generated during welding operations Wear protective goggles with side shields when removing slag Wear ear protection A loud acoustic shock is generated when discharging the capacitors 3 7 Before starting welding operations e Verify the state of all cables before starting a welding operation Immediately replace any faulty cables and cable connections Ensure that ventilation openings in the stud welder housing are not covered The Stud Welder may otherwise be damaged as a result of heat accumulation 3 8 Safety measures at the installation site 3 14 e e Ensure when installing the Stud Welder on tables or similar workshop furniture that the Stud Welder is positioned firmly and that the table or appropriate furniture can bear the appropriate load Ensure that the power socket and the Stud Welder have been connected to the ground properly Observe fire prevention regulations and do not carry out any welding operations in hazardous loc
12. Danger to persons by electric mechanic thermal and acoustic influences 3 4 Safety conscious working 3 12 The safety instructions stipulated in these Operating Instructions the existing national regulations governing accident prevention as well as possible interna tional work operating and safety regulations of the Operator must be observed soyer Safety instructions 3 5 Safety instructions for the User Operator In stud welding dangers may arise as a result of e e e e electric current optical radiation harmful substances fumes acoustic shocks spraying sparks You are therefore obliged to limit the dangers to an unavoidable minimum and to inform the Operator and other persons of such dangers AN MORTAL DANGER Persons with cardiac pacemakers must not operate the Stud Welder and must keep away from Stud Welders in operation 3 6 The following should be observed prior to initiation Before initiating the system the following points must be observed e The Stud Welding System must not be operated by juveniles below 16 years of age Read through the complete Operating Instructions before initiating the system Only qualified personnel is authorised to operate the system Prevent unauthorised use of the system by children or by unqualified personnel Wear non combustible closed working clothes Wear a leather apron over your work dress Weld spatters are generated during the
13. NG CAUTION or WARNUNG WARNING has been incorporated into safety references the non observance of which may lead to dangers for the machine and its functions General instructions are characterised with the following symbol 3 2 Staff qualification and training The staff designated for operation maintenance inspection and assembly must fulfil the qualifications required for these operations Field of responsibility competence and control of staff must be exactly regulated by the user If the staff do not possess the qualifications required these must be provided with the necessary training and instructions This can if necessary be implemented by the manufacturer supplier on behalf of the user Furthermore the user shall ensure that the contents of the Operating Instructions are fully understood by the personnel The Schwei technische Lehr und Versuchsanstalt M nchen SLV Training and Testing Institute of Welding offers appropriate training courses 3 3 Dangers resulting from non observance of safety instructions Non observance of safety instructions may not only represent danger to persons but also to the welding system and the environment If the safety instructions are not observed this may lead to a complete loss of warranty claims Non observance may for example lead to the following individual dangers Failure of important functions of the system Failure of prescribed methods for maintenance and repair
14. Operating Instructions Stud Welding Pistol PS 1 PS 3K PS OK PS 1K Soye n Operating Instructions Stud Welding Pistol PS 1 PS 3K PS OK PS 1K Serial number Stud Welding Pistol PS 1 Serial number Stud Welding Pistol PS 3K Serial number Stud Welding Pistol PS OK Serial number Stud Welding Pistol PS 1K Please mark your Stud Welding Pistol type here and enter the serial number so that these are available if you require service support Heinz Soyer Bolzenschweifstechnik GmbH Etterschlag Inninger Stra e 14 82237 W rthsee Phone 08153 885 0 Telefax 08153 8030 Telex 5270 295 heso d soyer Date of issue Dec 1 1994 SOYER is a registered trademark of Heinz Soyer Bolzenschweifstechnik GmbH It is prohibited to convey or reproduce this document as well as to utilise or disclose its contents unless this has been explicitly authorised In the event of noncompliance with this regulation damages will be charged All rights reserved in particular in the event of patent grant or GM registration This is to certify that we have verified the contents of this publication which comply with the hard and software described Deviations however cannot be excluded so that we cannot warrant for absolute compliance The specifications in this documentation have been verified regularly and necessary corrections incorporated into the following versions
15. We appreciate any suggestions for improvement Heinz Soyer Bolzenschwei technik GmbH 1994 All rights reserved Subject to technical modifications Printed in the Federal Republic of Germany Inninger Str 14 82937 Warthsee tterschlag F r den Anwendungsbereich Entwicklung Herstellung Vertrieb und Service der Bolzenschweifitechnik ein Qual ementsystem eingef hrt hat und anwendet Durch ein Audit wurde der Nachweis erbracht da dieses Qualit ts managementsystem die Anforderungen der Norm DIN EN ISO 9001 Ausgabe August 1994 erf llt Zertifikat Aegistrier Nr D 96 001 Zertifikat g ltig bis Feb 1999 D sseldorf don 18 1996 e Dipl Ing Pupp Dipl Ing M Lehmann soyer Table of Contents Table of Contents General information The following should be principally observed Intended use Information on the product Serial number Technology of tip ignition Stud Welding Pistol PS 1 Stud Welding Pistol PS 3K Stud Welding Pistol 5 0 Stud Welding Pistol PS 1K Technical data The following should be observed prior to initialisation Before starting welding operations Safety measures at the installation site Working with the Stud Welder Independent retrofitting and spare parts production Non permissible operating modes I HH H HB pmB mp HY 1 1 1 1 1 1 1 1 1 BP gt 9 QJ QJ QJ QJ QJ QJ QJ YY HH HI
16. and earthed Only trained personnel may use the Stud Welding Pistol AN MORTAL DANGER Persons with cardiac pacemakers must not operate the Stud Welder and must keep away from a Stud Welder during operation Ensure in particular that the Stud Welding System is not operated near electronically sensitive life saving equipment as in intensive wards in hospitals WARNING Ensure that sufficient distance to electronic equipment is kept Highly intensive electro magnetic fields are created in stud welding which may permanently damage these devices e g television sets e Furthermore observe the safety instructions stated in Chapter 3 Calla doctor in the event of an accident A MORTAL DANGER The S symbol is the symbol for welding current sources permitted for operation with increased electric danger The S symbol on our stud welders refers exclusively to the welding current circuit and not to the complete stud welder 1 1 General information soyer 1 2 Intended use 1 3 Information on 1 4 Serial number 1 2 With the SOYER Stud Welding Pistols PS 1 PS 3K PS OK and 5 1 operating with tip ignition a variety of pins and threaded bolts of steel and stainless steel can be welded dimensions see Chapter 2 6 Technical data It is also possible to weld fastening elements of brass The Stud Welding Pistol PS 1 15 also suitable for welding aluminium The visible side of the wor
17. ating Instructions carefully Principally operations may only be carried out when the Stud Welder has come to a standstill The procedure to bring the Stud Welder to a standstill described in the Operating Maintenance Instructions must be observed Immediately after completing the work ensure that all safety and protection features are restored and that these function 3 11 Independent retrofitting and spare parts production Retrofitting or modifications of the Stud Welder are only permissible with the manufacturer s approval Original spare parts and authorised accessories are designed to guarantee safety The use of any other parts may result in an annulment of warranty for any damages thus caused soyer Safety instructions 3 12 Non permissible operating modes Limit values Operational safety of the Stud Welder supplied can only be guaranteed if it is used in accordance with its purpose The limit values specified in the Technical Data must not be exceeded under any circumstances 3 16 soyer Setting the Stud Welding Pistol 4 Setting the Stud Welding Pistol 4 1 Setting the Stud Holder The stud holders of the Stud Welding Pistols PS 1 PS 3K PS 0K and PS 1K have the same construction If long welding studs are used it is however due to the short construction form of the Stud Welding Pistols PS OK and PS 1K necessary to appropriately shorten the stop screw 4 of the stud holders on these Welding Pistols
18. ations Ensure that the room is ventilated well or if necessary extract the welding vapours A DANGER TO HEALTH During welding operations vapours and suspended matters may be generated In particular beware of fumes detrimental to health when using surface treated materials If possible only carry out welding operations in rooms which have a room height exceeding 3 m Special regulations in accordance with VBG 15 are applicable for narrow rooms soyer Safety instructions 3 9 Working with the Stud Welder Observe all accident prevention regulations which are applicable for operating your Stud Welder gt The accident prevention regulation VBG15 Welding Cutting and similar work methods is applicable for Stud Welders For more information contact the employer s liability insurance association AN MORTAL DANGER Do not weld with work dress which is soiled with easily combustible substances such as oil grease paraffin oil etc If an accident happens Switch offthe Stud Welder disconnect the power supply and calla doctor 3 10 Safety instructions for maintenance inspection and assembly operations Only carry out maintenance work when the Stud Welder has come to a standstill The User shall ensure that all maintenance inspection and assembly operations are carried out by authorised and qualified technical personnel after having sufficiently informed himself by studying the Oper
19. eaflet 0903 German Welding Society This system utilises the abrupt discharge of a capacitor battery to generate electric arc energy Adjusting screw Stud holder ee oe lt _ Stud Workpiece Z 0001 E The electric arc is initiated via the calibrated and close fit ignition tip on the welding studs and the welding elements The stud weld base and the opposite surface of the workpieces is then melted slightly The stud is automatically immersed into the thin melted zone and or the liquid weld bath After the immediate solidification of the material an homogenous high strength joint in an extremely short welding time ranging only between 1 3 milliseconds 0 001 0 003 sec is achieved 2 5 soyer Description ofthe Stud Welder Pistols 2 2 Stud Welding Pistol PS 1 The SOYER Stud Welding Pistol PS 1 is designed for a wide variety of applications The field proven patented Positioning Pistol has a handy design is lightweight and is injection moulded of shock proof fully insulated plastic With this pistol the welding stud can be positioned exactly on a specific part of the workpiece without requiring any auxiliary aids Templates are not required Before welding the stud position has to be marked or centred slightly The calibrated igniti
20. ef Complete pistol cable comprising items 35 36 37 38 39 41 Threaded pin M8 x 8 Order No P02110 F01358 M01797 F01377 F01375 Fo1376 F01372 M01329 F01368 F01369 F01370 F01366 F01367 F01381 M01328 M01326 F01383 F01382 M01532 M01386 F01371 F01373 F01374 F01378 F01379 M01371 M01332 E02091 M01387 E02093 E02101 F01414 FA M01087 M01085 E02092 E02035 E01963 F01413 M01337 F01412 FA M02108 soyer 77 8 2 Perspective presentation of Stud Welding Pistol PS 1 Spare parts E So B 1 12 46 NS ER 147 SZ 0152 X 8 29 Spare parts soyer 8 3 Spare parts list for Stud Welding Pistol PS 3K 8 30 Item No Quantity Designation WWE HA HN H H HB FA pa pa pa nan HH mH mp p p HP H HF Stud Welding Pistol PS 3K comprising Stud holder M3 Stud holder M4 Stud holder M5 Stud holder M6 Stud holder M8 Union nut Rubber bellows Grounding foot Foot ring Foot ring special design Meiko reference diameter 43 mm Threaded pin M6 x 6 Delrin ring for bellows Working piston Piston sleeve Pistol sticker type designation Hand actuated auxiliary switch Cap red Cheese head screw M4 x 8 Countersunk screw M3 x 6 Insert nut M4 x 6 Threaded pin M4x8 Locking ring Threaded pin M4x8 Setting screw Sticker company address Protection sleeve Grounding foot special version
21. ficate see DVS Directive 0905 part 2 sections 4 1 and 4 2 The competence qualification is applicable in particular for fastening constructions concerning safety regulations If the Stud Welder is used in the construction industry only permissible base and stud materials see e g DIN 4100 clause 2 1 registration license for stainless steel ifBT DIN 4113 part 2 may be applied 6 4 Type and scope of testing 6 24 If the SOYER stud welding system is handled in compliance with regulations and the proper materials are selected the welded joint strength welding zone will always be higher than that of the stud or base material In practical operation the following work tests are carried out Normal work test see DVS Directive 0905 part 2 section 5 1 2 Simplified work test see DVS Directive 0905 part 2 section 5 1 2 soyer Quality Control 6 4 1 Normal work test Normal work tests are generally to be implemented and controlled by the Operator prior to carrying out welding works at a construction and after a certain number of welds The number of welds after which a normal work test is necessary is agreed with the customer The normal work test is restricted to the stud diameters base material and stud welder type used It includes the following tests Visual check samples Tension test at least 3 samples Bending test at least 3 samples In case of doubt the scope of testing should be extended
22. imum setting Samples should be taken several times during production to ensure that equally good welding results are achieved throughout the whole production process see DVS Directive 0905 part 2 How to ensure the quality of stud welding joints 4 19 soyer Initialisation 5 Initiation 5 1 General view The following diagram displays the Stud Welding Pistol PS 3K It only differs slightly from the Stud Welding Pistols PS 1 5 and PS 1K The Stud Welding Pistols PS OK and PS 1K are equipped with support tubes instead of the pistol feet 2 The Stud Welding Pistols PS OK and PS 1K are not equipped with a spring pressure display 5205 0594 016 1 Union nut 5 Connecting cable 2 Pistol foot 6 Release switch 3 Spring pressure display 7 Stud holder 4 Setting screw for spring pressure 5 20 soyer Initialisation 5 2 Connecting the Stud Welding Pistols to the Stud Welder 5 3 Operation The Stud Welding Pistols are connected to the Stud welder using the pistol and control cables Pistol Type Stud Welder BMS 660 90 BMS 690 135 8 Socket for connecting welding cable 9 Socket for connecting control cable Type Stud Welder BMS 6H BMS 8H 10 Socket for connecting welding cable 11 Socket for connecting control cable Z 0015 E Insert welding cable plug of the Stud Welding Pistol into the welding cable socket 8 10
23. in compliance with the DVS Directive 0905 part 2 section 5 1 1 6 4 2 Simplified work test Simplified work tests serve to control the correct stud welder setting and functioning of the equipment They are carried out before starting any shift or after any interruption lasting for several hours The simplified work test includes Visual check samples Bending test all samples 6 5 Implementation of sample taking 6 5 1 Production of samples 6 5 2 Visual check The studs for the work test are welded to a sheet metal the minimum size of which is 700 mm x 200 mm The same welding positions and distances to the borders shall be adhered to as on the construction part Identical parts to those to be used in later production should be used for the tests provided this is possible and economically justifiable The visual check serves as a rough control to detect any possible major faults The uniformity of the welding is assessed Tension or bending tests must be carried out in case of doubt Quality Control soyer 6 5 3 Tension test 6 5 4 Bending test 6 26 The tension test serves to test the metallic bond between the stud and the base material At least 3 studs are welded and then axially loaded by means of an appropriate tensile testing machine unitl they break If the Customer demands that a certain percentage of the welded studs should be tested with a predefined test load in production a tensile testing mach
24. ine with load unit display must be used If the stud breaks beyond the welding zone the sample test is regarded as successful If the stud breaks within the welding zone the fracture must be examined The unwelded surface must not exceed a maximum of 2096 of the welding surface In cases of doubt the breaking load is to be examined in accordance with DIN 267 part 3 If the number of faulty studs in any one random test exceeds the acceptance number in compliance with DIN 267 part 5 according to AQL 4 it is necessary to determine the reason for the faults In such a case it is necessary to modify the setting values and then repeat the test The bending test is a simple work test and is designed to roughly control the setting values selected An undefined tension pressure and bending is exerted on the welding zone At least 3 studs are welded and bent by 30 using an attached laterally ground tube The test is regarded as successful if no tear or fracture is detected in the welding zone The acceptance figure in compliance with DIN 267 part 5 according to AQL 4 must be observed If in one test batch the number of faulty parts exceeds the acceptance figure AQL 4 see DIN 267 the reason for the faults must be determined and the complete test repeated soyer Maintenance 7 Maintenance 7 1 Stud Welding Pistols The Stud Welding Pistols have been constructed in such a way to require only a minimum of maintenance The parts of the
25. istol PS 1K The SOYER Stud Welding Positioning Pistol PS 1K for stud welding with tip ignition is a shortened version of Stud Welding Pistol PS 3K see Chapter 2 3 It welds studs with ignition tips in accordance with DIN 32501 exactly on scribed surfaces or centre marks by means of spring pressure without any auxiliary aids It is particularly suitable for stud welding on workpieces and materials with impure surfaces such as zinc rolling skin forging scales and oxide films similar to the Stud Welding Pistol PS 3K It is designed for application in narrow and hardly accessible spaces due to its compact construction The Stud Welding Pistol PS 1K functions without backstroke and prevents a dislocation during the welding procedure It is suitable for all stud welding systems with tip ignition It is equipped with a sturdy shock and break proof whole body housing in a small and light weight version This closed pistol design guarantees additional stability and solidity advantages in contrast to the semimonocoque design The Stud Welding Pistol PS 1K corresponds to the latest state of the art in technology and fits like a glove similar to all other SOYER Stud Welding Pistols thanks to its excellent ergonomic design 124 5205 0594 015 2 9 Description of the Stud Welder Pistols soyer 2 6 Technical data PS 1 PS 3K PS OK PS 1K Welding range Threaded bolts M3 M8 M10 M3 8
26. ith the Operating Instructions and the necessary technical activities training is permitted to operate the Stud Welding System 1 5 3 Reaction in the case of malfunctions Important information if service is required If faults occur first try to determine and eliminate the error causes according to the error characteristics listed in the Operating Instructions in Chapter 12 Troubleshooting In all other cases contact our service department If you require service please ensure that the following information is available Customer number Product designation Serial number Construction year Options Stud and workpiece material Stud diameters e This information will help us and you to save time and unnecessary costs e g for false spare parts deliveries 1 6 Contact and service address 1 4 If you have any questions relating to the operation of your Stud Welding System retrofits or in any service case please contact your responsible service office or the following address Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger Stra e 14 D 82237 W rthsee Phone 08153 885 0 Telefax 08153 8030 Telex 52700295 heso d soyer Description of the Stud Welding Pistols 2 Description of the Stud Welding Pistols 2 1 Technology of tip ignition The SOYER Stud Welding Systems function according to the principle of capacitor discharge with tip ignition in compliance with DVS l
27. kpieces remain to a large extent unaffected by tool drag marks or deformation so that if thin metal sheets of below 1mm sheet thickness are welded a decorative appearance will be maintained Please contact either our parent company or one of our field engineers if you require consultation or a solution to your problem the product Manufacturer Heinz Soyer Bolzenschweifstechnik GmbH Etterschlag Inninger Stra e 14 D 82237 W rthsee Phone 08153 885 0 Telefax 08153 8030 Telex 52700295 heso d Product designation Stud Welding Pistol PS 1 Stud Welding Pistol PS 3K Stud Welding Pistol PS OK Stud Welding Pistol PS 1K Country of origin Germany The serial numbers of the Stud Welding Pistols are engraved into the handle General information 1 5 Information on the documentation The following Operating Instructions are delivered with the Stud Welding Pistols PS 1 PS 3K PS 0K and PS 1K Operating Instructions Stud Welding Pistol PS 1 PS 3K PS 0K and PS 1K Order No P00277 For subsequent orders please refer to Heinz Soyer Bolzenschweifstechnik GmbH Etterschlag Inninger Stra e 14 D 82237 W rthsee Phone 08153 885 0 Telefax 08153 8030 Telex 52700295 heso d 1 5 1 Chapters of Operating Instructions The Operating Instructions describe how to handle and setthe Stud Welding Pistols under normal conditions and comprise the following individual chapters Chapter 1 General Information Information on applicati
28. nut 3 NOTE The stud flange must project over the pistol feet tips and the support tube by the dimension of the flange thickness If necessary remove stud holder and correct projection by adjusting the stop screw 4 18 soyer Setting the Stud Welding Pistol 4 3 Setting the spring pressure The pressure with which the stud is pressed onto the workpiece during the welding process is referred to as spring pressure The following diagram displays the spring pressure setting for the Stud Welding Pistol PS 1 with spring pressure display The Stud Welding Pistol PS 3K is equipped with a similar spring pressure display The Stud Welding Pistols PS and PS 1K do not display the spring pressure Z05 0693 011 E 1 Setting screw 2 Spring pressure display The spring pressure can be set on all Stud Welding Pistols described using the same Setting screw 1 The spring pressure setting is displayed on the spring pressure scale 2 The spring pressure is set as follows Turn setting screw 1 to the left until it stops Display position 1 low pressure Turn setting screw 1 by 3 5 rotations to the right Display position 2 medium pressure Turn setting screw 1 to the right until it stops Display position 3 high pressure The spring pressure setting depends on the quality of the welding stud and of the workpiece Carry out welding samples and tests before starting work to determine an opt
29. on the product and supplementary information Chapter 2 Description of Stud Welding Pistols Description of tip ignition technology and of the Stud Welding Pistols Chapter 3 Safety instructions All relevant safety regulations regarding initiation and operation of the Stud Welding S ystem Chapter 4 Setting the Stud Welding Pistol Chapter 5 Initiation Chapter 6 Quality Control Chapter 7 Maintenance Maintenance measures Chapter 8 Spare parts Chapter 9 Troubleshooting Error characteristics possible causes and elimination of errors Chapter 10 Standards and list of directives Chapter 11 Warranty terms 1 3 General information soyer 1 5 2 Information on Operating Instructions Legal relationship We draw attention to the fact that the contents of these Operating Instructions are neither part of any former or existing agreement promise or legal relationship nor are designed to modify any such All obligations of Heinz Soyer Bolzenschwei technik GmbH result from the respective purchase agreement containing the complete and generally valid warranties These contractual warranty terms are neither extended nor limited by the implementation of these Operating Instructions WARNING It is prohibited to carry out any actions on the Stud Welding System without having exact knowledge of the Operating Instructions or of the respective part Ensure that only qualified personnel familiar w
30. on tip is then positioned on the marked point When the pistol is operated the stud is mechanically lifted A necessary air gap is created between the tip and the workpiece The stud is then mechanically moved to the marked point and is welded with electric arc ignition as soon as the marked point is reached The pistol guide is protected by rubber bellows especially against weld spatters and dirt A special spring pressure display with scale shows the spring pressure for the respective welding task and enables the reproducibility of welding joints if necessary 40 soyer Bolzenschwei er i Typ PS 1 derdruck T 321 Z05 0693 005 D 2 6 soyer Description of the Stud Welding Pistols 2 3 Stud Welding Pistol PS 3K The SOYER Stud Welding Positioning Pistol PS 3K for stud welding with tip ignition welds studs with ignition tip in accordance with DIN 32501 to exact positions on scribed surfaces or centre marks by means of spring pressure without any auxiliary aids It is particularly suitable for stud welding to workpieces and materials with impure surfaces such as zinc rolling skin forging scales and oxide films The Stud Welding Pistol PS 3K functions without backstroke and prevents a dislocation during the welding procedure It is suitable for all stud welding systems with tip ignition It is equipped with a sturdy shock and break proof whole body housing in a small and light weight version
31. orised persons or whenever accessories and spare parts have been used which do not match our equipment If welding studs purchased from other manufacturers are used we shall not warrant for the quality of any such welding joints Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger Stra e 14 D 82237 W rthsee Tel 49 0 81 53 8 85 0 Fax 49 0 81 53 80 30 Internet www soyer de www soyer com E Mail verkauf gsoyer de export soyer de
32. representative or Heinz Soyer Bolzenschweifstechnik GmbH directly You will find the address and telecommunication numbers in Chapter 1 6 on page 1 4 AN MORTAL DANGER Always disconnect the Stud Welder from the power supply by unplugging the power cord before opening the housing Only specially trained and appropriately qualified personnel is allowed to carry out works on the electric power supply and welding system AN WARNING Only trained and appropriately qualified personnel is authorised to replace any components of the Stud Welder Error Cause Error elimination System does not weld Stud welder is not switched ON no sparking Switch on system mains switch and green control lamp Operation must light up Welding cable or control cable are not connected correctly and or damaged Connect cable correctly and or examine to ensure that it is not damaged replace if necessary Both grounds are not or incorrectly connected and or ground clamps not connected to the workpiece gt Connect ground cable and or fasten ground clamps to the workpiece Welding points and or ground connections on the workpiece are not metalically blank Prepare workpiece and or stud 9 36 soyer Functional breakdowns Error Cause Error elimination No electric arc is generated even though system is ready for operation Stud without ignition tip or centre mark too deep for the
33. tation of Stud Welding Pistol PS OK 57 10 0001 8 33 Spare parts soyer 8 7 Spare parts list for Stud Welding Pistol PS 1K Item No Quantity Designation FA FA H pm p p pm pm pm p pm HJ F3 F3 F3 H3 FA H3 H3 NO Threaded pin M6 x 6 galvanised Supporting tube Guide sleeve Cap red Hand actuated auxillary switch Pistol half shell small Countersunk screw M3 x 6 Union nut Bellows Antikink coil Control cable 15 core Pistol cable complete PVC pin Threaded pin M8 x 8 PVC clip Cheese head screw M4 x 10 DIN 84 Spring washer M4 DIN 1274 Order No M01797 F02403 F02401 M01760 M02042 M01601 E02104 E02103 F01717 1 M01998 M01561 F01469 F02989 F01241 F02400 F02801 F01721 F01717 M01809 F01484 F02926 M01333 M01333 M01374 F02402 F01729 F02405 FA F01715 E02349 E02101 F01100 FA F03128 M01315 M01337 M02108 M01387 M01087 M01074 soyer Spare parts 8 8 Perspective presentation of Stud Welding Pistol PS 1K 57 10 0002 8 35 soyer Functional breakdowns 9 Troubleshooting The following list of errors their causes and elimination in tabular form are designed to help you to eliminate errors immediately on the spot If it is difficult or impossible to eliminate an error please contact your responsible SOYER Customer Service
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