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Vicks PS-1 manual

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Table of contents for the manual

  • Page 1

    Operating Instructions Stud Welding Pistol PS-1 PS-3K PS-0K PS-1K R[...]

  • Page 2

    R 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 her e and enter the serial number so that these are available if you r equire service support. Heinz Soyer Bolzenschweißtechnik GmbH Ettersc[...]

  • Page 3

    R SOYER  is a registered trademark of Heinz Soyer Bolzenschweißtechnik GmbH. It is prohibited to convey or repr oduce 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 r eserved, in particular in the e[...]

  • Page 4

    R[...]

  • Page 5

    Table of Contents i R T able 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 pr oduct __________________________________[...]

  • Page 6

    Table of Contents ii R 4. Setting the Stud W elding Pistol ____________________________________ 4-17 4.1 Setting the stud holder _________________________________________________ 4-17 4.2 Installing the stud holder in the Stud W elding Pistol _________________________ 4-18 4.3 Setting the spring pr essure ___________________________________________[...]

  • Page 7

    Table of Contents iii R 8. Spare parts ________________________________________________________ 8-28 8.1 Spare parts list Stud W elding Pistol PS-1 _________________________________ 8-28 8.2 Perspective presentation of Stud W elding Pistol PS-1 _______________________ 8-29 8.3 Spare parts list Stud W elding Pistol PS-3K ____________________________[...]

  • Page 8

    General information 1-1 R 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 p[...]

  • Page 9

    1-2 General information R 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 P[...]

  • Page 10

    General information 1-3 R 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 Bolzenschwei ß technik[...]

  • Page 11

    1-4 General information R 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 ß technik GmbH [...]

  • Page 12

    Description of the Stud Welding Pistols 2-5 R 2 Description of the Stud W elding Pistols 2.1 T echnology 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[...]

  • Page 13

    Description of the Stud Welder Pistols 2-6 R 2.2 Stud W elding 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 po[...]

  • Page 14

    Description of the Stud Welding Pistols 2-7 R 2.3 Stud W elding 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 particularl[...]

  • Page 15

    Description of the Stud Welder Pistols 2-8 R 2.4 Stud W elding 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 develo[...]

  • Page 16

    Description of the Stud Welding Pistols 2-9 R 2.5 Stud W elding 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 [...]

  • Page 17

    Description of the Stud Welder Pistols 2-10 R 2.6 T echnical data PS-1 PS-3K PS-0K PS-1K Welding range - Threaded bolts M3 - M8 M3 - M10 M3 - M8 M3 - M8 - Studs Ø 2 - 8 mm Ø 2 - 10 mm Ø 3 - 8 mm Ø 3 - 8mm Field of application 1* 2* 2* 3* Welding system Tip ignition in accordance with DVS Leaflet 0903 Welding and control cable 3 m highly flexibl[...]

  • Page 18

    Safety instructions 3-11 R 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 constantl[...]

  • Page 19

    Safety instructions 3-12 R 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 Staf f qualification and training The staff designated for operation, mai[...]

  • Page 20

    Safety instructions 3-13 R 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 pers[...]

  • Page 21

    Safety instructions 3-14 R • 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[...]

  • Page 22

    Safety instructions 3-15 R 3.9 W orking with the Stud W elder * 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 insur[...]

  • Page 23

    Safety instructions 3-16 R 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.[...]

  • Page 24

    Setting the Stud Welding Pistol 4-17 R 4. Setting the Stud W elding 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 approp[...]

  • Page 25

    4-18 Setting the Stud Welder Pistol R 4.2 Installing the stud holder in the Stud W elding 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 Pistol foot 4 Bellows 2 Stud holder 5 Sp[...]

  • Page 26

    Setting the Stud Welding Pistol 4-19 R 4.3 Setting the spring pr essure 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 i[...]

  • Page 27

    Initialisation 5-20 R 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[...]

  • Page 28

    Initialisation 5-21 R 5.2 Connecting the Stud W elding Pistols to the Stud W elder The Stud Welding Pistols are connected to the Stud welder using the pistol and control cables. • Insert welding cable plug of the Stud Welding Pistol into the welding cable socket (8/10) • Insert control cable plug of the Stud Welding Pistol into the control cabl[...]

  • Page 29

    Initialisation 5-22 R 5.4 W elding 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[...]

  • Page 30

    Initialisation 5-23 R 5.4.3 Stud Welder BMS-6H 5.4.4 Stud Welder BMS-8H M3 60 80 100 120 140 160 180 200 220 M4 M5 M6 M8 Stud diameter Charging voltage (V) SZ.0013.E M3 60 80 100 120 140 160 180 200 220 M4 M5 M6 M8 Stud diameter Charging voltage (V) SZ.0014.E[...]

  • Page 31

    Quality Control 6-24 R 6 Quality Contr ol 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[...]

  • Page 32

    6-25 Quality Control R 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 t[...]

  • Page 33

    Quality Control 6-26 R 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 pre[...]

  • Page 34

    7-27 Maintenance R 7. Maintenance 7.1 Stud W elding 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 hol[...]

  • Page 35

    Spare parts 8-28 R 8. Spar e parts 8.1 Spare parts list for Stud W elding Pistol PS-1 Item No. Quantity Designation Order No. Stud Welding Pistol PS-1 _______________ P02110 comprising 1 3 Grounding foot ________________________ F01358 3 2 Threaded pin M6 x 6 ___________________ M01797 4 1 Foot ring _____________________________ F01377 5 1 Union nu[...]

  • Page 36

    Spare parts 8-29 R 8.2 Perspective pr esentation of Stud W elding Pistol PS-1[...]

  • Page 37

    Spare parts 8-30 R 8.3 Spare parts list for Stud W elding Pistol PS-3K Item No. Quantity Designation Order No. Stud Welding Pistol PS-3K ______________ P02131 comprising 1 1 Stud holder M3 _______________________ F01151 Stud holder M4 _______________________ F01152 Stud holder M5 _______________________ F01153 Stud holder M6 _______________________[...]

  • Page 38

    Spare parts 8-31 R 8.4 Perspective pr esentation of Stud W elding Pistol PS-3K PS -3K R 21 1 2 4 4 3 5 6 7 8 4 6 15 (3x) 14 13 12 11 16 16 9 10 11 29 16 22 23 24 25 26 28 27 17 (3x) 18 15 19 20 30 31 4.1 5.1 6 4.1 4.1 6 32 33 34 36 37 38 39 35 SZ06.0993.025.X[...]

  • Page 39

    Spare parts 8-32 R 8.5 Spare parts list for Stud W elding Pistol PS-0K Item No. Quantity Designation Order No. 1 2 Cheese head screw M3 x 20, galvanised __ M01311 2 1 Support tube _________________________ F01472 3 2 Cheese head screw M3 x 6, galvanised ___ M01713 4 1 Centring plate _________________________ F01471 5 1 Union nut, galvanised _______[...]

  • Page 40

    Spare parts 8-33 R 8.6 Perspective presentation of Stud Welding Pistol PS-0K PS-0K 10 1 2 3 5 6 7 4 8 11 17 13 14 15 8 24 16 19 18 23 20 9 12 11 21 22 25 SZ.10.0001.X[...]

  • Page 41

    Spare parts 8-34 R 8.7 Spare parts list for Stud W elding Pistol PS-1K Item No. Quantity Designation Order No. 1 2 Threaded pin M6 x 6, galvanised _________ M01797 2 1 Supporting tube _______________________ F02403 3 1 Guide sleeve __________________________ F02401 4 2 Spring dowel sleeve Ø 3 x 8 _____________ M01760 5 1 Pistol sticker PS-1K _____[...]

  • Page 42

    Spare parts 8-35 R 8.8 Perspective pr esentation of Stud W elding Pistol PS-1K PS -1K R 8 7 9 10 11 14 16 33 17 15 19 12 13 18 11 5 4 1 2 3 1 26 25 24 22 21 20 31 30 29 30 38 37 28 36 27 23 32 4 6 34 35 SZ.10.0002.X[...]

  • Page 43

    Functional breakdowns 9-36 R 9 T r oubleshooting 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 Bolzenschwei ß[...]

  • Page 44

    9-37 Functional breakdowns R Error Cause → Error elimination No electric arc is generated, Stud without ignition tip or centre mark too deep for the ignition tip even though system is → Use stud with ignition tip or reduce centre mark ready for operation Fault in Stud Welder control and/or at the Stud Welding Pistol → Inform SOYER Customer Se[...]

  • Page 45

    Standards and List of Directives / Warranty Terms 10/11-38 R 10. Standards and List of Dir ectives • DIN 4100 Welded steel constructions with primarily dead load • DIN 267, part 5 Screws, nuts and similar parts, technical delivery terms, examination and acceptance • DIN 17100 General construction steels, quality standard • DIN 8563, part 10[...]

  • Page 46

    Heinz Soyer Bolzenschweißtechnik GmbH Etterschlag Inninger Stra ß e 14 D-82237 W ö rthsee T el.: ++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 .de[...]