Operating Instructions Stud Welding Pistol PS-1 PS-3K PS-0K PS-1K R
R Operating Instructions Stud Welding Pistol PS-1 PS-3K PS-0K PS-1K Serial number* Stud Welding Pistol PS-1 Serial number* Stud Welding Pistol PS-3K Serial number* Stud Welding Pistol PS-0K 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.
R SOYER is a registered trademark of Heinz Soyer Bolzenschweißtechnik 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.
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R Table of Contents Table of Contents 1. General information ________________________________________________ 1-1 1.1 1.2 1.3 1.4 1.5 1.5.1 1.5.2 1.5.3 1.6 The following should be principally observed ..
R Table of Contents 4. Setting the Stud Welding Pistol ____________________________________ 4-17 4.1 4.2 4.3 Setting the stud holder _________________________________________________ 4-17 Installing the stud holder in the Stud Welding Pistol _________________________ 4-18 Setting the spring pressure _____________________________________________ 4-19 5. Initiation __________________________________________________________ 5-20 5.1 5.2 5.3 5.4 5.4.1 5.4.2 5.4.3 5.4.
R Table of Contents 8. Spare parts ________________________________________________________ 8-28 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.
R General information 1 General information 1.1 The following should be principally observed ... With this Stud Welding Pistol you have purchased a product which • 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: • Store the Operating Instructions in a place to which every Operator has access.
R General information 1.2 Intended use With the SOYER® Stud Welding Pistols PS-1, PS-3K, PS-0K and PS-1K 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 is also suitable for welding aluminium.
R 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 Bolzenschweißtechnik GmbH Etterschlag Inninger Straße 14 D-82237 Wörthsee Phone 08153-885-0 Telefax 08153-8030 Telex 52700295 heso d 1.5.
R General information 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 Bolzenschweißtechnik GmbH result from the respective purchase agreement containing the complete and generally valid warranties.
R 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 leaflet 0903 (German Welding Society). This system utilises the abrupt discharge of a capacitor battery to generate electric arc energy. Adjusting screw Stud holder Stud Workpiece SZ.0001.
R Description of the 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.
R Description of the Stud Welding Pistols 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.
R Description of the Stud Welder Pistols 2.4 Stud Welding Pistol PS-0K The SOYER® Stud Welding Positioning Pistol PS-0K 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.
R Description of the Stud Welding Pistols Stud Welding Pistol 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.
R Description of the Stud Welder Pistols 2.6 Technical data PS-1 PS-3K Welding range - Threaded bolts - Studs M3 - M8 Ø 2 - 8 mm M3 - M10 M3 - M8 Ø 2 - 10 mm Ø 3 - 8 mm M3 - M8 Ø 3 - 8mm Field of application 1* 2* 3* Welding system 1* 2* 3* 2-10 2* PS-1K Tip ignition in accordance with DVS Leaflet 0903 Welding and control cable Weight without cable PS-0K 3 m highly flexible 0.5 Kg 0.
R 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.
R Safety instructions The word ACHTUNG (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.
R Safety instructions 3.5 Safety instructions for the User/Operator In stud welding dangers may arise as a result of • • • • • 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. MORTAL DANGER Persons with cardiac pacemakers must not operate the Stud Welder and must keep away from Stud Welders in operation. 3.
R Safety instructions • 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 ...
R Safety instructions 3.9 Working with the Stud Welder * Observe all accident prevention regulations which are applicable for operating your Stud Welder ☞ 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. MORTAL DANGER Do not weld with work dress which is soiled with easily combustible substances such as oil, grease, paraffin oil etc.
R Safety instructions 3.12 Non-permissible operating modes Limit values 3-16 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.
R 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-0K and PS-1K necessary to appropriately shorten the stop screw (4) of the stud holders on these Welding Pistols. 1 3 2 4 1,5 SZ06.0593.012.
R 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-0K and PS-1K are equipped with a support tube instead of the pistol feet (1). 1 2 3 4 5 6 SZ05.0693.010.
R 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 PS0K and PS-1K do not display the spring pressure. 2 1 Spring pressure 3 2 1 SZ05.
R 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, PS-0K and PS-1K. * The Stud Welding Pistols PS-0K and PS-1K are equipped with support tubes instead of the pistol feet (2). * The Stud Welding Pistols PS-0K and PS-1K are not equipped with a spring pressure display. 1 2 3 PS-3K 7 4 6 R 5 SZ05.0594.016.
R Initialisation 5.2 Connecting the Stud Welding Pistols to the Stud Welder 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 8 9 10 11 Type Stud Welder BMS-6H, BMS-8H 10 Socket for connecting welding cable 11 Socket for connecting control cable SZ.0015.
R 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. AlMg3 and StVK were used as stud material, AlMg3 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.
R Initialisation 5.4.3 Stud Welder BMS-6H 220 Charging voltage (V) 200 180 160 140 120 100 80 60 M3 M4 M5 M6 M8 Stud diameter SZ.0013.E 5.4.4 Stud Welder BMS-8H 220 Charging voltage (V) 200 180 160 140 120 100 80 60 M3 M4 M5 M6 M8 Stud diameter SZ.0014.
R Quality Control 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 Bolzenschweißtechnik GmbH is a member of the Deutscher Verband für Schweißtechnik e.V.
R 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.
R Quality Control 6.5.3 Tension test 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 machine with load unit display must be used.
R 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 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.
R Spare parts 8. Spare parts 8.1 Spare parts list for Stud Welding Pistol PS-1 Item No. 8-28 Quantity Designation 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 3 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 41 1 Order No.
R Spare parts 8.
R Spare parts 8.3 Spare parts list for Stud Welding Pistol PS-3K Item No. 8-30 Quantity Designation 1 1 2 3 4 4.1 5 5.1 1 1 3 3 1 1 6 7 8 9 10 11 12 13 2 1 1 1 1 2 1 1 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 1 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Order No.
R Spare parts Perspective presentation of Stud Welding Pistol PS-3K 6 5.1 8 4.1 5 6 7 4 4.1 4 6 4.1 3 2 6 1 15 (3x) 4 14 21 20 R 8.4 19 13 16 12 16 K PS 15 -3 11 37 18 38 16 36 32 17 (3x) 9 35 11 10 30 39 29 33 27 28 23 24 25 22 26 34 31 SZ06.0993.025.
R Spare parts 8.5 Spare parts list for Stud Welding Pistol PS-0K Item No. Quantity Designation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 8-32 2 1 2 1 1 1 1 2 1 1 1 3 1 1 1 3 4 1 1 1 1 1 1 1 1 Order No.
R Spare parts 8.6 Perspective presentation of Stud Welding Pistol PS-0K 3 6 5 2 7 1 4 15 14 13 11 8 24 25 -0 K 8 S 17 P 18 20 23 19 16 10 9 12 22 11 21 SZ.10.0001.
R Spare parts 8.7 Spare parts list for Stud Welding Pistol PS-1K Item No. Quantity Designation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 8-34 2 1 1 2 1 1 1 1 1 3 2 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Order No.
R Spare parts Perspective presentation of Stud Welding Pistol PS-1K 3 2 1 1 10 9 R 8.8 17 8 16 14 7 11 33 K PS -1 15 4 12 11 5 27 28 13 37 38 30 34 35 19 29 36 4 23 32 18 26 6 21 22 31 24 20 25 30 SZ.10.0002.
R 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 representative or Heinz Soyer Bolzenschweißtechnik GmbH directly. You will find the address and telecommunication numbers in Chapter 1.6 on page 1-4.
R Functional breakdowns Error No electric arc is generated, even though system is ready for operation Cause → Error elimination Stud without ignition tip or centre mark too deep for the 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 Varying welding results Stud holder worn down → Replace stud
R Standards and List of Directives / Warranty Terms 10.
Heinz Soyer Bolzenschweißtechnik GmbH Etterschlag Inninger Straße 14 D-82237 Wörthsee 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@soyer.de export@soyer.
