Vicks PS-3K, PS-0K, PS-1, PS-1K User Manual

Operating Instructions

Stud Welding Pistol PS-1 PS-3K PS-0K PS-1K

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.

Heinz Soyer Bolzenschweißtechnik GmbH Etterschlag Inninger Straße 14 82237 Wörthsee

Phone 08153 - 885 - 0 Telefax 08153 - 8030 Telex 5270 295 heso d

Date of issue: Dec. 1, 1994

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. 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. We appreciate any suggestions for improvement.

Table of Contents

1. General information ________________________________________________ 1-1

1.1 The following should be principally observed ..______________________________1-1

1.2 Intended use __________________________________________________________1-2

1.3 Information on the product ______________________________________________1-2

1.4 Serial number _________________________________________________________1-2

1.5 Information on the documentation ________________________________________1-3

1.5.1 Chapters of Operating Instructions________________________________________1-3

1.5.2 Information on the Operating Instructions __________________________________1-4

1.5.3 Reaction in the case of malfunctions ______________________________________1-4

1.6 Contacts and service adress_____________________________________________1-4

2. Description of the Stud Welding Pistols _____________________________ 2-5

2.1 Technology of tip ignition ________________________________________________2-5

2.2 Stud Welding Pistol PS-1________________________________________________2-6

2.3 Stud Welding Pistol PS-3K ______________________________________________2-7

2.4 Stud Welding Pistol PS-0K ______________________________________________2-8

2.5 Stud Welding Pistol PS-1K ______________________________________________2-9

2.6 Technical data ________________________________________________________2-10

3. Safety instructions ________________________________________________ 3-11

3.1 Characterisation of references in the Operating Instructions__________________3-11

3.2 Staff qualification and training ___________________________________________3-12

3.3 Dangers resulting from non-observance of safety instructions ________________3-12

3.4 Safety-conscious working ______________________________________________3-12

3.5 Safety instructions for the User/Operator__________________________________3-13

3.6 The following should be observed prior to initialisation ... ____________________3-13

3.7 Before starting welding operations ..._____________________________________3-14

3.8 Safety measures at the installation site ___________________________________3-14

3.9 Working with the Stud Welder___________________________________________3-15

3.10 Safety instructions for maintenance, inspection and assembly operations ______3-15

3.11 Independent retrofitting and spare parts production ________________________3-15

3.12 Non-permissible operating modes _______________________________________3-16

Table of Contents

4. Setting the Stud Welding Pistol ____________________________________ 4-17

4.1 Setting the stud holder_________________________________________________4-17

4.2 Installing the stud holder in the Stud Welding Pistol_________________________4-18

4.3 Setting the spring pressure _____________________________________________4-19

5. Initiation __________________________________________________________ 5-20

5.1 General view _________________________________________________________5-20

5.2 Connecting the Stud Welding Pistols to the Stud Welder ____________________5-21

5.3 Operation ____________________________________________________________5-21

5.4 Welding parameters ___________________________________________________5-22

5.4.1 Stud Welder BMS-660-90______________________________________________5-22

5.4.2 Stud Welder BMS-690-135_____________________________________________5-22

5.4.3 Stud Welder BMS-6H__________________________________________________5-23

5.4.4 Stud Welder BMS-8H__________________________________________________5-23

6. Quality control_____________________________________________________ 6-24

6.1 General information ___________________________________________________6-24

6.2 Demands on the company _____________________________________________6-24

6.3 Proof of qualification ___________________________________________________6-24

6.4 Type and scope of testing ______________________________________________6-24

6.4.1 Normal work tests_____________________________________________________6-25

6.4.2 Simplified work tests___________________________________________________6-25

6.5 Implementation of sample taking ________________________________________6-25

6.5.1 Production of samples _________________________________________________6-25

6.5.2 Visual check _________________________________________________________6-25

6.5.3 Tension test __________________________________________________________6-26

6.5.4 Bending test _________________________________________________________6-26

7. Maintenance ______________________________________________________ 7-27

7.1 Stud welders _________________________________________________________7-27

7.2 Replacing components ________________________________________________7-27

Table of Contents

8. Spare parts________________________________________________________ 8-28

8.1 Spare parts list Stud Welding Pistol PS-1 _________________________________8-28

8.2 Perspective presentation of Stud Welding Pistol PS-1_______________________8-29

8.3 Spare parts list Stud Welding Pistol PS-3K ________________________________8-30

8.4 Perspective presentation of Stud Welding Pistol PS-3K _____________________8-31

8.5 Spare parts list Stud Welding Pistol PS-0K ________________________________8-32

8.6 Perspective presentation of Stud Welding Pistol PS-0K _____________________8-33

8.7 Spare parts list Stud Welding Pistol PS-1K ________________________________8-34

8.8 Perspective presentation of Stud Welding Pistol PS-1K _____________________8-35

9. Troubleshooting ___________________________________________________ 9-36

10. Standards and list of directives _______________________________ 10/11-38

11. Warranty terms_______________________________________________ 10/11-38

iii

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.

• 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 and earthed.

• Only trained personnel may use the Stud Welding Pistol.

General information

 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).

• Furthermore, observe the safety instructions stated in Chapter 3.

• Call a doctor in the event of an accident.

 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

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.

The visible side of the workpieces 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.

1.3 Information on the product

Manufacturer Heinz Soyer Bolzenschweißtechnik GmbH

Product designation Stud Welding Pistol PS-1

Country of origin Germany

1.4 Serial number

The serial numbers of the Stud Welding Pistols are engraved into the handle.

Etterschlag Inninger Straße 14 D-82237 Wörthsee Phone 08153-885-0 Telefax 08153-8030 Telex 52700295 heso d

Stud Welding Pistol PS-3K Stud Welding Pistol PS-0K Stud Welding Pistol PS-1K

1-2

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

General information

1.5.1 Chapters of Operating Instructions

The Operating Instructions describe how to handle and set the Stud Welding Pistols under normal conditions and comprise the following individual chapters:

• Chapter 1 “General Information” Information on application, 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 System

• 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

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. 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 with 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

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.

Important information If you require service, please ensure that the following information is available: if service is required

• Customer number

• Product designation

• Serial number

• Construction year

• Options

• Stud and workpiece material

• Stud diameters

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 Bolzenschweißtechnik GmbH Etterschlag Inninger Straße 14 D-82237 Wörthsee Phone 08153-885-0 Telefax 08153-8030 Telex 52700295 heso d

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

Workpiece

Stud

SZ.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

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.

Before welding the stud position has to be marked or centred slightly. The calibrated ignition 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.

211

Ø 6

Federdruck

321

Ø 40

Ø 34

Bolzenschweißer

Typ PS-1

3x120°

132

2-6

SZ05.0693.005.D

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. This closed pistol design guarantees additional stability and solidity advantages in contrast to the semimonocoque design.

Description of the Stud Welding Pistols

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.

235

ø 40

ø 34

3x120°

PS-3K

138

SZ06.0593.003.X

2-7

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