Operating Instructions Stud Welder BMS-8N
Contents
1. d El SS T Gees N SZ 0138 X 1 Stud 3 Lock nut 2 Stud holder 4 Stop screw Different stud holders are required for different stud diameters Adjust the stud holder as follows e Loosen lock nut 3 e Insert stud 1 into stud holder The top edge of the stud flange must project for about 1 5 mm from the front edge of the stud holder LS The stud must come into contact with the stop screw 4 e Adjust stop screw 4 in the stud holder by turning it until the distance from the top edge of the stud flange to the front edge of the stud holder is 1 5 mm Secure stop screw 4 by means of lock nut 3 Revision 1 A 1 soyer Appendix A PS 1 and PS 1K Adjustment of stud welding pistols Tip ignition Installation of stud holder into stud welding pistols PS 1 and PS 3K The illustration below shows how to install the stud holder into the stud welding pistols PS 1 and PS 3K SZ 0136 X 1 Pistol leg 4 Bellows 2 Stud holder 5 Spring piston 3 Sleeve nut 6 Stud flange e Loosen sleeve nut 3 by means of socket wrench SW 17 e Insert stud holder 2 into spring piston 5 until it stops e Tighten stud holder 2 by means of the sleeve nut 3 LS The stud flange must project beyond the top of the pistol legs or the support tube for the thickness of the flange If need be remove stud holder and correct the projection by means of the stop screw2. Revision 1 soyer Appendix A PS 1 and PS 1K Adjustment of stud welding pistols Tip ignition 1 3 Installation of stud holder into stud welding pistol PS 1K and PS OK The illustration below shows how to install the stud holder into the stud welding pistol PS 1K These instructions are also applicable for stud welding pistol PS OK Z 0133 E 1 Stud holder 2 Support tube e Loosen sleeve nut by means of socket wrench SW 14 e Insert stud holder 1 into spring piston until it stops e Tighten stud holder 1 by means of the sleeve nut Remove the support tube 2 to easily install the stud holder LS The stud flange must project beyond the top of the pistol legs or the support tube for the thickness of the flange If need be remove the stud holder and correct the projection by means of the stop screw Revision 1 A 3 soyer Appendix A PS 1 and PS 1K Adjustment of stud welding pistols Tip ignition 1 4 Adjustment of spring pressure A 4 The pressure with which the stud is pressed against the workpiece during the welding process is called spring pressure The illustration below shows how to adjust the spring pressure of stud welding pistol PS 1 which is equipped with a spring pressure indicator The stud welding pistol PS 3K is equipped with a similar spring pressure indicator The welding pistols PS OK and PS 1K do not have a spring pressure indicator 1 Z 0
3. Check the state of all cables before starting to weld Immediately replace defective cables and cable connections Ensure that the air apertures of the housing are not covered Heat accumu lation may damage the stud welder 3 8 Safety precautions at installation site H e When placing the stud welder on tables or similar workshop furniture ensure that the stud welding system stands firmly and that the table can bear its weight Make sure mains socket and stud welder are properly earthed Comply with fire prevention regulations and do not weld in hazardous locations Make sure room is well ventilated or extract welding fumes if necessary A DANGER TO HEALTH When welding fumes and suspended matters may be generated Beware of fumes detrimental to health particularly when using surface treated materials If possible only weld in rooms which are higher than 3 m As per VBG 15 special regulations are applicable for narrow rooms 3 12 Revision 1 soyer Safety instructions 3 9 Working with the stud welder e Comply with all accident prevention regulations which apply to the operation of your stud welder LS One of the accident prevention regulations applicable for stud welders is VBG15 Welding cutting and similar working methods For more information contact the Employer s Liability Insurance Association A MORTAL DANGER When welding do not wear clothes soiled with easily combustible
4. Sleeve nut Bellows Grub screw M4 x6 Cheese head screw Pistol half shell small contained in item 19 Push button 1 pole Cap PVC Pistol label PS 1K Pistol label company address Cylindrical pin 6 x 36 Flat head screw M3 x 6 Complete pistol housing Insert nut M4 x 6 Spring retainer Pressure spring PVC pin Adjusting screw Earth cable complete stranded conductor Strain relief Spring washer M4 PVC clip Grub screw M5 x8 Grub screw M8 x 8 Anti kink sleeve Control cable complete with plug Pistol cable complete with plug comprising Earth connector SKM 25 Earth cable 25 mm2 Order No F03813 F03890 M01338 F03812 M03541 M03542 F03823 F01469 F02989 F03815 M01315 M01998 not numbered E02103 E02104 F03824 M02042 M01601 M03594 M01561 F03811 FA M01809 F03814 F03891 F02397 M01333 M01374 F02402 M01315 F03128 F01729 F02405 FA F01715 M01087 M01074 M01387 M01337 M02108 E02349 E02101 F01100 FA E01963 E02035 Revision 1 soyer Appendix A PS 1 and PS 1K Spare parts Tip ignition 3 2 Exploded view of stud welding pistol PS 1K Z 0177 X Revision 1 A 9 soyer Appendix A PS 1 and PS 1K Spare parts Tip ignition A 10 Revision 1 soyer Beiblatt zu BMS 8N 2 Supplement to BMS 8N 2 Anderung der Netzspannung auf 115 230 Volt Alteration of mains voltage to 115 230 volt IN LEBENSGEFAHR Ziehen Sie vor dem ffnen des Geh uses der B
5. welding system under normal conditions and comprise the following chapters in detail e Chapter 1 General Information on application and product as well as supplementary informa tion e Chapter 2 Description of stud welder Description of tip ignition technology and of the stud welder Chapter 3 Safety instructions All safety regulations which are relevant with regard to initiation and opera tion of the stud welding system e Chapter 4 Installation of stud welder e Chapter 5 Initiation e Chapter 6 Quality control e Chapter 7 Maintenance Maintenance measures Chapter 8 Spare parts e Chapter 9 Troubleshooting Errors possible causes and remedies e Chapter 10 Transport and storage e Chapter 11 List of standards and guidelines e Chapter 12 Terms of warranty Revision 1 1 3 General soyer 1 5 2 Information on operating instructions Legal relationship We draw your attention to the fact that the contents of these operating instruc tions are neither part of any former or existing arrangement pledge or legal relationship nor are designed for modifying the latter All obligations of Heinz Soyer Bolzenschwei technik GmbH result from the respective contract of purchase which also comprises the complete and generally valid warranties These contractual warranty terms are neither extended nor restricted by the implementation of these operating instructions WARNING Do not carry out any
6. dangers to an inevitable degree and to point these dangers out to the operator and other persons involved A MORTAL DANGER Persons with pacemakers must neither operate the stud welder nor stay near it 3 6 The following should be observed before starting the system Before starting the system pay attention to the following information e J uveniles under the age of 16 years must not operate the stud welding system e Read all of the operating instructions before starting the system e Only qualified personnel are allowed to operate the system e Prevent unauthorized use of the system by children or unqualified personnel e Wear non combustible closed working clothes e Wear a leather apron to protect your clothes from welding spatters that are generated during the welding process e Wear a head protection when carrying out welding works above your head A MORTAL DANGER When welding do not wear clothes soiled with easily combustible substances such as oil grease and paraffin oil etc Revision 1 3 11 Safety instructions soyer e e e e 3 7 Before starting H e e Wear gauntlet gloves made of leather Wear neither rings watches nor electrically conductive jewellery Wear protective goggles to protect your eyes from welding spatters and flashes of light that are generated during the process Wear ear protection Capacitor discharge generates a loud bang welding
7. gt If the error message E 5 appears please do not switch off the stud welder The stud welder is ready for welding again after it has cooled down E 6 Software fault or hardware failure Elimination by SOYER customer service only E 7 Hardware failure in charging circuit Elimination by SOYER customer service only Revision 1 9 33 Malfunctions 9 2 Troubleshooting Error Cause Elimination System does not weld no sparking System is not switched on Switch on system LED Ready and charging voltage display must light up Welding cable or control cable are not connected properly or damaged Connect cables properly or check for damage Replace if necessary Both earth cables are not connected or are not properly connected and or earth clamps are not attached to the workpiece Connect earth cables attach earth clamps to the workpiece Welding points and or earth connection points at the workpiece are not metallically blank Prepare workpiece and or studs System is switched on but does not function Mains supply is defective Check mains supply fuse Fuse of stud welder is defective Replace defective fuse see chapter 7 3 There is no arc even though system is ready for operation Stud without ignition tip or centre mark too deep for the ignition tip Use stud with ignition tip or reduce centre mark Control of stud welder or welding pist
8. it should be protected against dampness and dust e Please pay particular attention to the bearing strength of the workshop furniture and ensure a safe and stable position e Make sure there is sufficient free space around the air apertures e Install the stud welder close to the welding location Ensure correct connected loads with mains operation e The electrical connecting cable used for mains operation is of adequate length Additional extension cables cause a voltage drop possibly leading to unit disturbances e Ensure sufficient ventilation of the working room when operating the system LS The housing of stud welder BMS 8N corresponds to safety class IP 21 Please observe e g that this system of protection is not suitable for being operated or transported in the rain Revision 1 4 15 Initiation soyer 5 Initiation 5 1 Total view Front view Rear view I H soyer BMS 8N e ccls Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger Str 14 82237 W rthsee Tel 0 81 53 885 0 12 1 Function key Arrow up Increase of charging voltage 2 Charging voltage display 3 Function key Arrow down Decrease of charging voltage 4 LED displays 5 Earth cable connectors Z 0126 X 6 Welding cable soc
9. or Heinz Soyer Bolzenschwei technik GmbH For address and telecommunication data please refer to chapter 1 6 page 1 4 IN MORTAL DANGER Always disconnect the connecting plug from the mains socket before open ing the housing of the stud welding system Only trained and appropriately qualified personnel are allowed to carry out works on the electric power supply and stud welder A WARNING Only trained and appropriately qualified personnel are allowed to replace components of the stud welding system A MORTAL DANGER Before replacing components ensure that the capacitors are discharged 9 32 Revision 1 Malfunctions 9 1 Error codes The stud welder switches off when malfunctions occur The charging voltage of the capacitors is internally discharged An error message appears as code on the charging voltage display item 2 chapter 5 1 Errorcode Description Possible cause E 1 Safety circuit activated Welding operating error E 2 Charging duration exceeded Charging fuse defective E 3 Internal error Safety circuit defective E 4 Mains voltage not in order Mains voltage deviation too large 115 230 V AC 10 15 LS The error message is acknowledged by switching the stud welder off and then switching it on again If the error message appears again please inform the customer service responsible for your area E 5 Excess temperature of transformer Excessive welding cycle I
10. stud welding systems with tip ignition run according to the principle of capacitor discharge as defined in DVS Leaflet 0903 German Welding Society This system uses the abrupt discharge of a capacitor battery to generate electric arc energy 3 Bazar INES Stud tip touches work Ignited arc generates a Stud immerses in welding piece Electric arc is thin fusion zone on stud pool Material solidifies initiated and workpiece and stud is welded Z 0078 E The electric arc is initiated via the calibrated and close fit ignition tip on the welding studs and welding elements The stud weld base and the opposite surface of the workpiece are melted on The stud is then automatically dipped in the thin fusion zone or liquid weld pool After the immediate solidification of the material an homogenous high strength joint is produced in an extremely short welding time of only 1 3 milliseconds 0 001 0 003 sec 2 2 Stud welder set up The standard pistol to be connected to the stud welder BMS 8N is the stud welding pistol PS 1K with control cable Optionally it is possible to connect the stud welding pistols PS OK PS 1 and PS 3K These operating instructions exclusively describe the stud welder BMS 8N For information regarding the stud welding pistols required and their setting please refer to the respective operating instructions of the stud welding pistols Description of stud welding system 2 3 Dimensions The stud
11. to connect the stud welding pistol to the stud welder Mains connector item 12 chapter 5 1 The mains connector is located at the rear side of the stud welder Use the mains cable supplied to connect the stud welder to the power supply 5 17 Initiation soyer 5 1 4 Symbols 5 1 5 Fuse elements Symbol Description Function 000 Digital display of Digital display of charging voltage in volts measured values Function key Arrow up Increase of charging voltage Function key Arrow down Decrease of charging voltage LED Malfunction LED lights up when stud welder fails LED Ready LED lights up when stud welder is ready for operation LED Stud on LED lights up when earth terminal is workpiece connected and stud touches the workpiece LED Release LED lights up when trigger switch on welding pistol or weldig head is pressed Stud diameter Symbol for stud diameter Ce Earth Marks where earth cable connectors are for earth cable connection Pistol Marks where control and welding cable A sockets are for pistol connection Z 0128 E The stud welder BMS 8N is protected by the following fuses Mains supply fuses Charging fuse F1 Control fuse F2 Fuse for ventilator F3 2x10Aslow Plug in unit item 10 chapter 5 1 6 3 A slow Control board S0 115 1A slow Contr
12. welder BMS 8N has a handy and compact design It has a carrying handle and can be optionally equipped with a shoulder strap 300 120 ESE soyer BMS 8N e ce S 2 6 Depth 320 mm Z 0124 E Revision 1 Description of stud welding system 2 4 Technical data Description BMS 8N Welding range M3 M8 or 3 7 1mm Material Steel stainless steel Aluminium and brass conditionally depending on the respective requirements Welding method Tip ignition according to DVS Leaflet 0903 Standard pistol Stud welding pistol PS 1K Current source Capacitor battery Charging capacity 66 000 uF Charging voltage 50 200 V infinitely variable up down Welding time 0 001 0 003 sec Welding sequence up to 20 studs min depending on stud diameter Mains supply 115 230 V AC 50 60 Hz 10 16 AT shock proof socket automatic voltage selection 115 230 V AC Fuse element G fuse link 5 x 20 mm 2 x 10 A slow 250 V The fuse links are integrated in the unit mounting plugs at the rear side of the stud welders Welding cable 3 m highly flexible Earth cable 2 x 3 highly flexible Weight 10 kg Colour RAL 5009 azure Subject to technical changes Z 0125 E Revision 1 2 7 Description of stud welding system 2 5 Block diagram
13. 137 E 1 Adjusting screw 2 Spring pressure indicator The spring pressure for all stud welding pistols described here is adjusted by means of the adjusting screw 1 The adjusted spring pressure is indicated on the spring pressure scale 2 Adjust the spring pressure as follows e Turn adjusting screw 1 to the left until stop Indicator position 1 low pressure Turn adjusting screw 1 3 5 turns to the right Indicator position 2 medium pressure Turn adjusting screw 1 to the right until stop Indicator position 3 strong pressure e e The adjustment of spring pressure depends on the material of both the welding stud and the workpiece Before starting work carry out some experimental welds and test them to find out the optimum adjustment Several samples have to be taken during production to ensure constantly good welding results see DVS Guideline 0905 part 2 Quality assurance of stud welding joints Revision 1 soyer Appendix A PS 1 and PS 1K Initiation Tip ignition 2 Initiation 2 1 Total view The illustration below shows stud welding pistol PS 3K The indicated compo nents are only slightly different from those of stud welding pistols PS 1 PS 3 PS OK and PS 1K e The stud welding pistols PS OK and PS 1K are equipped with support tubes instead of pistol legs 2 e The stud welding pistols PS OK and PS 1K are not equipped with a spring pressure indicator The stud welding pistol PS 1K is optio
14. 9 F03950 M01244 E03795 M03641 Revision 1 soyer j y Spare parts 8 4 Exploded view of BMS 8N stud welder View A Z 0175 X Revision 1 8 29 Spare parts soyer 8 5 Spare parts list for BMS 8N stud welder View B C and D 8 30 Item No OONADUBWNE Quantity Description NPNPBRBBRBRPRPNNFPRPABNNFPBRPRPRPEPBRBNNPFPBRPRPRP PEN Flat head screw M3x10 Mains switch Varistor Rear panel of housing Washer M4 Fan 24VDC Spring ring M6 Washer M6 Spring ring M3 Spacing bolt M4x20 synthetic Panel jack 15 pole Copper bar Hexagon nut M4 Spring ring M4 Wire resistor 3 9R Resistor mounting plate Distance sleeve 7x1 4x10mm Front panel Earth connector SEM 25 Earth socket BEM 25 Order No M01348 03685 01347 E03607 E03635 F03939 M01062 E03684 M01073 M01011 M01221 M01012 M03584 M01076 M01707 E03689 M03538 F03941 FA M01001 M01073 M03550 E03714 F03942 M01012 M01074 E02881 E03687 F01296 M01261 F03944 FA E01964 E01958 M03576 Revision 1 soyer j y Spare parts 8 6 Exploded view of BMS 8N stud welder View B C and D Z 0176 X Revision 1 8 31 Malfunctions 9 Malfunctions The following list of errors their causes and remedies is designed to help you eliminate any trouble immediately on the spot If it is difficult or impossible to eliminate the trouble please contact the SOYER customer service responsible for your area
15. Operating Instructions BMS 8N eo soyer Operating Instructions Stud Welder CE ousau Serial number Stud Welder BMS 8N Please enter the serial number so that this data is immediately available if you need service support Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger StraBe 14 82237 Worthsee Phone08153 885 0 Fax 08153 8030 Telex 5270 295 heso d soyer Date of issue revision 1 Aug 1 2000 SOYER is a registered trade mark of Heinz Soyer Bolzenschwei technik GmbH Itis prohibited to transmit or reprint this document as well as to utilize or disclose its contents unless this has been expressly granted Non compliance with this regulation is liable to compensation All rights reserved particularly in the case of a patent grant or GM registration We have certified that the contents of this pamphlet correspond to the hard and software described Deviations however cannot be excluded so that we cannot warrant for absolute compliance The data in this documenta tion however have been verified regularly and necessary corrections will be incorporated in future impressions We appreciate any suggestions for improvement Heinz Soyer Bolzenschwei technik GmbH 1995 All rights reserved Subject to technical alterations Printed in the Federal Republic of Germany soyer EC Conformity Declaration in compliance with EC Directive on Machiner
16. YER servicemen prior to initiation LS The housing of stud welder BMS 8N corresponds to safety class IP 21 Please observe e g that this system of protection is not suitable for being operated or transported in the rain 10 36 Revision 1 soyer Standards and guidelines 11 List of standards and guidelines Revision 1 H 91 368 EEC formerly 89 392 EEC 73 23 EEC 93 31 EEC formerly 89 336 EEC EN 292 1 EN 292 2 EN 60204 1 formerly VDE 0113 EN 60974 1 EN 292 2 VGB 1 VBG 5 DIN 4100 DIN 267 part 5 DIN 17100 DIN EN ISO 14555 DIN EN ISO 13918 DIN 50049 DIN 50125 DIN 54111 part 1 DVS Leaflet 0902 DVS Guideline 0905 part 1 EC Directive on Machinery EC Directive on Low Voltage EC Directive on Electromagnetic Compatibility Safety of machinery basic terms general principles of construction basic terminology systems engineering Technical principles specifications Electric equipment of machinery general requirements Safety requirements for arc welding equipment part 1 welding current sources Operating instructions General instructions instructions for accident prevention Power operated equipment instructions for accident prevention Welded steel structures with predominantly dead load Screws nuts and the like technical terms of delivery testing and acceptance Constructional steels general types quality standard Arc welding of
17. activities on the stud welding system without specifi cally knowing the operating instructions or the respective part Ensure that only qualified personnel familiar with the operating instructions and the necessary technical activities training operate the system 1 5 3 Conduct in the case of malfunctions Important information if service is required If malfunctions occur first try to detect and eliminate the causes according to the list in chapter 9 Troubleshooting In all other cases contact our service department If you require our service please make sure that you supply the following information Customer number Product designation Serial number Year of construction Options Material of stud and workpiece Stud dimensions e e e e e e o This information will help us both to save time and unnecessary costs e g caused by delivering the wrong spare parts 1 6 Contacts and service address 1 4 If you have any questions regarding the operation of the stud welding system retrofits or if you require service 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 Fax 08153 8030 Telex 52700295 heso d E Mail export soyer de verkauf soyer de Revision 1 Description of stud welding system 2 Description of stud welder 2 1 Tip ignition technology The SOYER
18. d instructed If necessary this can be done by the manufacturer supplier on behalf of the welding equipment user Furthermore the user must ensure that the contents of the operating instructions are fully understood by the staff The training and testing institute of welding in Munich SLV Schwei technische Lehr und Versuchsanstalt offers the appropriate training courses for your personnel 3 3 Dangers in the case of non compliance with safety instructions The non compliance with safety instructions may not only endanger persons but also the welding system and its environment Any non compliance with Safety instructions may result in a complete loss of damage claims Non compliance with safety instructions may have the following conse quences e Failure of important system functions e Failure of prescribed methods for maintenance e Danger to persons through electric mechanic thermal and acoustic influences 3 4 Safety conscious working The safety instructions listed in this manual existing national accident preven tion regulations and possible international working operating and safety regulations of the user must be complied with 3 10 Revision 1 soyer Safety instructions 3 5 Safety instructions for the operator user When stud welding danger may result from e electric current e optical radiation e harmful substances smoke acoustic shock e spraying sparks You are therefore obliged to restrict the
19. d work tests serve to check the correct setting and function of the equipment They are carried out at the beginning of every working shift and after several hours of interruption Simplified work tests include e Visual inspection all samples e Bend test all samples 6 5 Test execution 6 5 1 Production of samples 6 5 2 Visual inspection 6 22 The studs for the work test are welded on a sheet metal the minimum size of which is 700 mm x 200 mm Use the same welding positions and edge dis tances as on the component to be welded later If it is possible and sensible from an economical point of view use parts that are identical to those used in later production The visual inspection serves as a rough check for major defects The uniformity of the weld is assessed When in doubt tensile and bend tests should be carried out Revision 1 soyer Quality control 6 5 3 Tensile test 6 5 4 Bend test Revision 1 The tensile test serves to test the metallic bond of the stud with the base metal At least 3 studs are welded and then axially loaded by means of an appropriate tension device until they break If the customer demands that a certain percentage of the welded studs should be tested with a specific test load in production a tension device with load indicator should be used If the stud breaks outside the welding zone the test is regarded as successful If it breaks within the welding zone however the fractured
20. der LGA EMC Test Center Testing Body f Tillystr 2 D 90431 N rnberg Germany Inhaber der Bescheinigung Heinz Soyer Bolzenschwei technik GmbH Holder of certificate Inninger Str 14 D 82237 W rthsee Etterschlag Hersteller dto Manufacturer Pr fbericht vom 25 Jan 22 April 1999 Technical Report Date Auftr Nr Order no 429 1043 Objektbezeichnung Bolzenschwei er Object Identification Typ type BMS 8N Pr fbeschreibung EMV Pr fungen Test Description EMC Tests Pr fstandards EN 50 199 EN 61 000 3 2 EN 61 000 3 3 Standards Diese Konformit tsbest tigung wurde gem Artikel 10 Abs 1 der Richtlinie des Rates vom 03 Mai 1989 zur Angleichung der Rechtsvorschriften der Mitgliedsstaaten ber die elektromagnetische Vertr glichkeit 89 336 EWG vom EMV Pr fzentrum der LGA erstellt Die Best tigung macht keine Aussagen in bezug auf die Schutzanforderungen zur elektromagnetischen Vertr glichkeit nach anderen Rechtsvorschriften die der Umsetzung anderer Richtlinien der Europ ischen Union als der EMV Richtlinie dienen Diese Best tigung bezieht sich auf das gepr fte Muster This Confirmation of Conformity was issued by the EMC Test Center of the LGA in accordance with Article 10 1 of the Council Directive 89 336 EEC on the approximation of the laws of the Member States relating to electromagnetic compatibility This certificate does not contain any statements pertaining to the EMC protection requirements p
21. e _ Z lt lt 10 36 11 List of standards and guidelines ______ nn 11 37 12 Terms of warranty __ _ Z 12 38 Appendix A PS 1 and PS 1K Tip ignition 1 Adjustment of stud welding pistol LI A 1 1 1 Adjustment of stud holder 2222 A 1 1 2 Installation of stud holder into stud welding pistols PS l and PS 3K ________ 2 20 0 000000 2000 A 2 1 3 Installation of stud holder into stud welding pistols PS 1K and PS OK eee A 3 1 4 Adjustment of spring pressure 22222 A 4 2 Initiation Tonen E endete inte mars art ee a et Tote to A 5 2 1 Total VIEW ee Se e er a ya eh nt Beine ns erh E A 5 2 2 Connecting stud welding pistols to stud welder eee A 6 2 3 Operation A 6 3 Spare parts Z A 7 3 1 Spare parts list for stud welding pistol PS IK 2 20 2000 00 oo LI A 8 3 2 Exploded view of stud welding pistol PS 1K A 9 Revision 1 soyer General 1 General 1 1 The following should be principally observed With this stud welder you have purchased a product which e is state of the art technology e fully complies with the current safety requirements and e enables successful working Before putting the stud welder into operation always observe the following Store the operating instructions in a place accessible to every operator Ensure that the respective operator has read and understood the operating instructions prior to installation Each operator should confirm this by signa ture e Prevent the stud welder being opera
22. e Bute ee 5 18 5 1 5 Fuse elements 5 18 5 2 Preparation for initiation 0 5 19 5 2 1 Earth Connection 5 19 5 2 2 Connection of stud welding pistol 5 19 5 2 3 Mains supply 5 19 5 3 Operation TAs Ee BB a ae a ee Ba ee ee 5 20 5 4 Welding parameters 5 20 Revision 1 soyer Contents 6 Quality control LLLIN 6 21 6 1 General 0000000 LI 6 21 6 2 Demands on the company _ 00000000 6 21 6 3 Proof of qualification 6 21 6 4 Type and Scope OF test ee ee een be ale 6 21 6 4 1 Standard work test 0 000000 LI 6 22 6 4 2 Simplified work test 6 22 6 5 Test execution 6 22 6 5 1 Production of sample 6 22 6 5 2 Visual inspection 6 22 6 5 3 EI Ce A PRE Re E a AA AS SAE a 6 23 6 5 4 Bendtest ______ _ 2 2 2 0000 LLLLLLN 6 23 7 Maintenance ss 7 24 7 1 St d TESS rn ande Ara 7 24 7 2 Replacement of components 7 24 7 3 FUSES a a ole e e A ta As hs ne ee neh E aT 7 25 8 Spare parts t anaa a a a a a a a 8 26 8 1 Spare parts list for stud welder BMS 8N Overview eee 8 26 8 2 Exploded view of stud welder BMS 8N Overview 8 27 8 3 Spare parts list for stud welder BMS 8N View A 0 Lo LI 8 28 8 4 Exploded view of stud welder BMS 8N View A eee 8 29 8 5 Spare parts list for stud welder BMS 8N View B Cand D eee 8 30 8 6 Exploded view of stud welder BMS 8N View B Candbn O 8 31 9 Malfunctions 4 _ _ _ Be Ee ee Eege 9 32 9 1 Error codes _ _ 22 9 33 9 2 Troubleshooting n rras e e a ee aa nen a EE u 9 34 10 Transport and storag
23. ee 1 4 1 5 3 Conduct in the case of malfunctions 1 4 1 6 Contacts and service address 1 4 2 Description of stud welder _ Z Z Z Z Z 222 2 5 2 1 Tip ignition technology 2 2 2 5 2 2 Stud welder set up 2 5 2 3 Dimensions 0 0 0000 2 6 2 4 Wechnial data EES 2 7 2 5 Block diagram 0 000000 oo L 2 8 3 Safety instructions 3 9 3 1 Description of reference signs in the operating instructions eee 3 9 3 2 Staff qualification and training 22222 3 10 3 3 Dangers in the case of non compliance with safety instructions 3 10 3 4 Safety conscious working 0 2 2 0 LI 3 10 3 5 Safety instructions forthe operator user 000000000 LI 3 11 3 6 The following should be observed before starting the system 2 2222222222 3 11 3 7 Before starting welding 0 20 0000 0 LI 3 12 3 8 Safety precautions at installation site 3 12 3 9 Working with the stud welder 0000000000000 LI 3 13 3 10 Safety instructions for maintenance inspection and assembly works 22222222S OoOO 3 13 3 11 Unauthorized retrofit and spare parts production 3 13 3 12 Inadmissible operating methods ee 3 14 3 13 Stopping the stud welder 2 200000 0 oo LI 3 14 3 14 The S symbol 000000000000 oo LI 3 14 4 Installation of stud welder 4 15 5 Initiation 5 16 5 1 WOtal VIEW ee es ah es eens bce let he ee nr Ge 5 16 5 1 1 Operating elements 5 17 5 1 2 Display elements 5 17 5 1 3 Connecting elements 2 22 5 17 5 1 4 SYMONS u vt rte an aaa ne Lea A AE RN el Get sche alate cle maint at
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25. esponsible specialist staff prior to assembly and initiation They must always be 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 listed under the other main items have to be complied with 3 1 Description of reference signs in the operating instructions The non observance of safety instructions can cause damage to persons The safety instructions of this manual are marked with the general symbol for danger safety symbol in compliance with DIN 4844 W9 Warning of electric voltage is specially marked with the safety symbol in compliance with DIN 4844 W8 In addition to these symbols the words DANGER TO HEALTH or MORTAL DANGER refer to the degree of a possible danger Revision 1 3 9 soyer Safety instructions Safety instructions the non observance of which may endanger the machine and its functions are marked with the terms CAUTION or WARNING General instructions are marked with the hand symbol is 3 2 Staff qualification and training The staff responsible for operation maintenance inspection and assembly must have the respective qualification for carrying out these works Field of responsibility competence and the supervision of staff has to be exactly regulated by the user If your personnel do not have the necessary knowledge they have to be trained an
26. essure incorrectly set Set spring pressure Welding pistol in tilted position Ensure that all 3 pistol legs are simultaneously and evenly positioned on the workpiece Base metal not weldable Use suitable material combinations System does not weld Release period of 0 6 sec exceeded after pressing the pistol trigger switch Trigger handle of welding pistol PS 1 too slowly pulled Pistol trigger switch incorrectly set or defective Welding pistol mechanically defective e g jammed or sluggish piston Release period For safety and welding quality reasons the ignition tip of the welding stud must touch the workpiece and be ignited within 0 6 sec after pressing the pistol trigger switch The welding process is not released when exceeding this period of time Revision 1 Transport and storage 10 Transport and storage The stud welder is sturdily designed and has a two piece metal case with front and rear panel Owing to the electronic components however please ensure that transport is free from vibrations The stud welder BMS 8N is equipped with a carrying handle for easy transport The unit suitcase GK 2 is the optimum solution for storing and transporting the stud welder BMS 8N and the stud welding pistol PS 1K Prevent unauthorized use of the stud welding system by children and unquali fied personnel After long system standstill we recommend having the stud welder checked by SO
27. he fastening of structures that are relevant in terms of safety regulations When being used in the building industry only approved base and stud materials may be used for example see DIN 4100 section 2 1 certificate of approval for stainless steel ifBT DIN 4113 part 2 6 4 Type and scope of test Revision 1 Provided thatthe SOYER stud welding system is properly used and the materials are appropriately selected the strength of the welding joint welding zone will always be stronger than that of the stud or base material The follow ing tests are carried out in general practice Standard work test see DVS Guideline 0905 part 2 section 5 1 2 e Simplified work test see DVS Guideline 0905 part 2 section 5 1 2 6 21 Quality control soyer 6 4 1 Standard work test Generally standard work tests have to be carried out and supervised by the user before welding at a structure and after a certain number of welds has been made The number of welds after which a standard work test is required is agreed upon with the customer The standard work test is restricted to the stud diameter base material and type of equipment used It comprises the following tests e Visual inspection all samples Tensile test at least 3 samples e Bend test at least 3 samples In case of doubt the test scope should be extended in compliance with DVS Guideline 0905 part 2 section 5 1 1 6 4 2 Simplified work test Simplifie
28. ket 7 Control cable connection 8 Carrying handle 9 Mains switch 10 Fuses 11 Type plate 12 Mains connector Revision 1 soyer Initiation 5 1 1 Operating elements 5 1 2 Display elements Mains switch item 9 chapter 5 1 The mains switch located at the rear side of the stud welder serves to switch the stud welder on and off Function key Arrow up item 1 chapter 5 1 The function key Arrow up 1 enables continuous increase of the charging voltage for larger stud diameters for setting values refer to the table Function key Arrow down item 3 chapter 5 1 The function key Arrow down 3 enables continuous decrease of the charging voltage for smaller stud diameters for setting values refer to the table Charging voltage display item 2 chapter 5 1 The digital display shows the adjusted energy value charging voltage in volts LED display item 4 chapter 5 1 The LED display shows the respective operational states 42 4 3 L 4 4 4 1 LED Malfunction 4 2 LED Ready 4 3 LED Release 4 4 LED Stud on workpiece Z 0127 E 5 1 3 Connecting elements Revision 1 Earth cable connectors item 5 chapter 5 1 The earth cable connectors serve to connect the earth terminals to the stud welder Welding cable socket item 6 chapter 5 1 and control cable connection item 7 chapter 5 1 The control cable connection and the welding cable socket serve
29. lacing the printed circuit board and or the clearly arranged fuses IN MORTAL DANGER Before replacing any components disconnect the mains cable from the mains supply Electric and electronic components may only be replaced by a Specialist Contact the SOYER service department if necessary 7 2 Replacement of components Defective components may only be replaced by trained SOYER servicemen Perfect function of your stud welder can only be guaranteed when original SOYER spare parts are used A MORTAL DANGER Ensure that the capacitors are discharged before replacing any compo nents Revision 1 soyer Maintenance 7 3 Fuses The stud welder BMS 8N is protected by the following fuses Mains supply fuses 2x10Aslow Plug in unit item 10 chapter 5 1 Charging fuse F1 6 3 A slow Control board S0 115 Control fuse F2 LA slow Control board S0 115 Fuse for ventilator F3 250 mA slow Control board S0 115 IN DANGER TO HEALTH Should it become necessary to replace fuses only use fuses with the specified electrical values Oversized fuses could either cause defects to the electrical system or a fire IN MORTAL DANGER Disconnect the mains plug from the mains supply when replacing fuses Revision 1 7 25 soyer Spare parts 8 Spare parts 8 1 Spare parts list for BMS 8N stud welder Overview Item No Quantity Description Order No 1 1 Upper part of housing F03938 2 2 R
30. lder BMS 8N were determined by using the stud welding pistols PS 1 and PS IK The charging voltages shown in the table on the right are standard values They vary from the stated setting depending on the material type workpiece thickness 5Z 0129 X and surface condition ofthe workpiece 5 20 Revision 1 soyer Quality control 6 Quality control 6 1 General The 0905 DVS Guideline part 2 of April 1979 is applicable with regard to quality assurance of stud weld joints The tests described in this section are written in simplified terms following above regulation They refer to work tests that are carried out and supervised by the user prior to and during welding Heinz Soyer Bolzenschwei technik GmbH is a member of the German Welding Society DVS Deutscher Verband fur Schwei technik e V Munich 6 2 Demands on the company The company must employ a technical supervisor responsible for welding matters as well as qualified operating personnel for stud welding see DVS Guideline 0905 part 2 section 4 6 3 Proof of qualification In the case of components which documentation must be provided for or stud welding works which as per DIN 4100 DIN 4113 are subject to acceptance the processing company must submit a certificate of competence or a proof of qualification for working with stud welding equipment see DVS Guideline 0905 part 2 sections 4 1 and 4 2 The proof of qualification applies in particular to t
31. metallic materials Studs and ceramic ferrules for arc welding Certificate on material tests Testing of metallic materials tensile tests guidelines for production Non destructive method of testing Arc welding with retract ignition Quality assurance of stud welding joints 11 37 Terms of warranty 12 Terms of warranty We warrant for this equipment for a period of 6 months in accordance with our conditions of sale and delivery Any claim to a warranty will be forfeited if damage is caused by improper operation or if repairs or interferences have been made by unauthorized persons or whenever accessories and spare parts have been used which do not match our equipment We cannot guarantee the quality of welding joints if welding studs acquired from another company are used 12 38 Revision 1 soyer Appendix A PS 1 and PS 1K Adjustment of stud welding pistols Tip ignition 1 Adjustment of stud welding pistol 1 1 Adjustment of stud holder The stud holders of stud welding pistols PS 1 PS 3K PS OK and PS 1K are all of the same style When using long welding studs with the welding pistols PS OK and PS 1K however it is necessary to shorten the stud holders stop screw 4 due to these pistols small size LS For pistols PS 1 PS 3K PS OK and PS 1K use the standard stud holder of 40 mm length with adjusting screw Ensure that the maximum stud length does not exceed 35 mm C pri DPN
32. nally available with 3 pistol legs Z 0135 X 1 Sleeve nut 5 Connecting cable 2 Pistol leg 6 Push button 3 Spring pressure indicator 7 Stud holder 4 Adjusting screw for spring pressure Revision 1 A 5 soyer Appendix A PS 1 and PS IK Initiation Tip ignition 2 2 Connecting stud welding pistols to stud welder 2 3 Operation A 6 The stud welding pistols are connected to the stud welder by means of pistol and control cables e Connect stud welder to earth e Connect stud welding pistol as described in chapter 5 e Adjust welding pistol as described in Appendix A Chapter 1 e Connect stud welder to the mains supply e Adjust stud welder for the welding studs to be used e Insert welding stud into stud holder e Position stud welding pistol on the workpiece and press push button Revision 1 soyer Appendix A PS 1 and PS 1K Spare parts Tip ignition 3 Spare parts Revision 1 A 7 Appendix A PS 1 and PS 1K Spare parts Tip ignition soyer 3 1 Spare parts list for stud welding pistol PS 1K A 8 Item rR FPFOWOONDUBWNNF Fa m me Quantity Description ewer k k k OI 4 mW Ww k PP RPP kA kA kA kA kA kA kA kA kA kA kA kA kA kA kA D kA b kA kA kA kA kA k w 3 Support tube 30 mm Pistol leg optional Grub screw optional Support tube retainer Grub screw M6 x5 Grub screw with spring M4 x 10 Insulating ring
33. of BMS 8N 2 8 Relay SP2 5VDC F1 6 3AT S0115 revision 2 Machine PCB F2 1A Control nm DS a Ventilator F3 250mA 26VDC Measuring Flat cable SO105 revision 1 Front panel 15 pole socket Trigger Pistol Zu Bg z w Jon a 2 a mL ER GE Re 5 g e 5 ei EI oF Own H sti re 2 Ly A yellow green 3 K275 brown SR black brown green 8 ellow y F white QS aie gt g z gt ba 5 oh sl 5 S i amp Bees a EI Di ES 5 d SE m st mmm gt gt N a o 5 S si g gt g al za 8 R red a blue 3 Charging red el module blue a black blue blue red red white red brown brown 100W green Dart Discharging SKR 130 16 resistor R Ly J 22mF L kd 22mF O e kd e 22mF Gd lt Om Y m Gate A nH Cathode 100W 139 Eu Safety resistor i i FN ei D Bo a Ww WwW amp 5Z 0178 E Revision 1 soyer Safety instructions 3 Safety instructions These operating instructions contain basic instructions which have to be complied with during installation and or operation It is therefore absolutely necessary that these operating instructions are read by the operator and r
34. ol board S0 115 250 mA slow Control board S0 115 Revision 1 soyer Initiation A WARNING Should it become necessary to replace fuses only use those with specified electrical values Oversized fuses could either cause defects to the electrical system or a fire A MORTAL DANGER Always disconnect the mains plug from the power supply when replacing fuses 5 2 Preparation for initiation Connect the stud welding pistol and the earth cables to the stud welder prior to initiation 5 2 1 Earth connection e Connect earth cables to earth cable connectors item 5 chapter 5 1 and lock by turning to the right until stop e Connect earth clamps to the workpiece LS Ensure optimum contact with workpiece 5 2 2 Connection of stud welding pistol e Connect welding cable of welding pistol to the welding cable socket item 6 chapter 5 1 and lock by turning to the right until stop e Insert control cable into the control cable socket item 7 chapter 5 1 and secure with both locking screws e Please observe the connecting instructions see operating instructions for the welding pistols 5 2 3 Mains supply Insert mains cable into mains connector item 12 chapter 5 1 and connect to the power supply IN MORTAL DANGER Only connect stud welder to authorized shock proof sockets Revision 1 5 19 soyer Initiation 5 3 Operation Switch on mains switch The 4 LED displa
35. ol is defective Inform SOYER customer service Stud is too loose in stud holder Press stud holder together or tighten it Stud thread scorched Stud holder worn Replace stud holder Varying welding results Welding energy not correctly adjusted Adjust welidng energy Cable connections are too loose Transition resistances are generated Check all cable connections and earth clamps for tight fit Stud too loose or not fully inserted into stud holder until stop Insert stud into stud holder until stop If necessary replace stud holder Varying welding results Magnetic blowing action Arc is forced into a certain direction Alter earth clamp fixture place iron parts on the edges and or rotate welding pistol Revision 1 Malfunctions Error Cause Elimination Intensive sparking stud flange almost melted away Welding energy is set too high Reset welding energy Stud not welded with total flange surface deficient weld joint strength Welding energy is set too low Reset welding energy Poor earth connection Check earth cables and earth clamps for tight fit tighten if necessary Workpiece surface too soiled Clean workpiece surface Stud weld base deformed Use new welding studs Stud projection over stud holder incorrectly set Set projection to 2 3 mm distance between stud holder and stud weld base Spring pr
36. olzenschwei anlage grunds tzlich den Anschlussstecker aus der Netzanschlussdose Nur ausgebildetes und entsprechend qualifiziertes Personal darf Arbeiten an der elektrischen Stromversorgung und Anlage durchf hren A MORTAL DANGER Always disconnect the connecting plug from the mains supply socket before opening the housing of the stud welding equipment Only trained and appropriately qualified personnel are allowed to carry out works on the electric power supply and stud welder O O O Steuerplatine SO 115 Rev 3 SMD Steuerplatine SO 115 Rev 3 SMD Fi Control printed circuit SO 115 Rev 3 5 Control printed circuit SO 115 Rev 3 setting 115V AC VEER setting 230V AC Contra printed irel ev F4 115V F5 230 V F6 230 V DIS Ells O O O F1 6 3AT O Netzspannung Line voltage 115 Volt AC Netzspannung Line voltage 230 Volt AC Sicherung 10AT in Sicherungshalter F4 und F7 einsetzen Sicherung 10AT in Sicherungshalter F5 und F6 einsetzen Insert fuse 10AT into F4 and F7 fuse holders Insert fuse 10AT into F5 and F6 fuse holders 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 soy
37. red to a large extent from pressure marks or deformations so that even thin sheet metals under 1 mm sheet thickness retain their decorative appearance If you need consultation or assistance in solving problems please contact either our parent company or our field engineers the product Manufacturer Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger StraBe 14 D 82237 W rthsee Phone 08153 885 0 Fax 08153 8030 Website http www soyer de national http www soyer com international Product designation Stud welder BMS 8N Country of origin Germany The type plate is located on the rear side of the stud welder It contains the following information Manufacturer s name Manufacturer s address Country of origin Product designation Method of welding Date of construction Production number Performance data Mains connection values e e e e e e e e e Revision 1 soyer General 1 5 Information on the documentation The following operating instructions are supplied with the BMS 8N stud welder e Operating instructions for stud welder BMS 8N Order no P00298 For repeat orders please contact Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger StraBe 14 D 82237 W rthsee Phone 08153 885 0 Fax 08153 8030 Telex 52700295 heso d E mail export soyer de verkauf soyer de 1 5 1 Chapters of the operating instructions The operating instructions describe the initiation and operation ofthe stud
38. substances such as oil grease and paraffin oil etc If an accident happens e switch off the stud welder and disconnect it from the mains supply e calla doctor 3 10Safety instructions for maintenance inspection and assembly works Only carry out maintenance The user must ensure that all maintenance inspection and assembly works when stud welder has works are only carried out by authorized and qualified technical personnel been switched off Generally only work at the system when it has been switched off and after having disconnected it from the mains supply It is indispensable to comply with the procedure for stopping the stud welding system described in the operating instructions chapter 3 13 Immediately after having completed your work re install and activate all safety and protective devices 3 11Unauthorized retrofit and spare parts production The system may only be retrofitted and modified after consultation with the manufacturer Original spare parts and accessories authorized by the manufac turer guarantee safety The use of other parts may result in the cancellation of warranty for any consequences thus caused Revision 1 3 13 Safety instructions soyer 3 12Inadmissible operating methods Limit values Working safety of the stud welding system supplied can only be guaranteed when the stud welder is used in accordance with its purpose The limit values indicated in the chapter Technical data m
39. surface must be examined The unwelded surface may not exceed a maximum of 20 of the welding surface When in doubt the breaking load in accordance with DIN 267 part 3 should be determined If the quantity of defective studs in one random test exceeds the acceptance number specified in DIN 267 part 5 as per AQL 4 it is necessary to find out the reason for the faults The setting values must be modified and the test repeated The bend test is a simple work test which serves to roughly check the setting values selected The welding zone is subjected to undefined tension pressure and bending A minimum of 3 studs is welded and bent to an angle of 30 by means of a tube that is slipped over the stud The test is considered as suc cessful if no superficial fissure or fracture is detected in the welding zone The acceptance number in accordance with DIN 267 part 5 as per AQL 4 must be complied with If the quantity of defective parts in one inspection lot exceeds the acceptance number AQL 4 see DIN 267 the cause of trouble must be determined and the test repeated again Maintenance soyer 7 Maintenance 7 1 Stud welder The stud welder is constructed in such a way that only a minimum of mainte nance is required The interior ofthe stud welder should however be cleaned at regular intervals depending on the environmental conditions at the location of use Any defects ofthe system s control part can easily be eliminated by rep
40. ted by unauthorized persons e Only trained personnel may operate the stud welder IN MORTAL DANGER Persons with pacemakers must not operate the stud welder and must not stay in the vicinity of the stud welder while it is running Ensure that the stud welder is not operated near electronically sensitive life supporting equipment such as in intensive care units in hospitals WARNING Keep sufficient distance from electronic devices When stud welding highly intensive electromagnetic fields are created which may permanently damage these devices e g television sets e Moreover observe the safety instructions in chapter 3 Call a doctor in case of an accident IN 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 Revision 1 1 1 General soyer 1 2 Application 1 3 Information on 1 4 Type plate 1 2 The SOYER stud welder BMS 8N with tip ignition allows you to weld pins and threaded studs of M3 M8 or 3 7 1 mm as well as numerous various fastening elements made of steel and stainless steel see chapter 2 4 Techni cal Data It is also possible to weld fastening elements made of aluminium and brass depending on the respective requirements The visible side of the workpiece is spa
41. ubber foot internal M01121 3 8 Washer M4 nylon M01251 01 4 8 Fillister head screw M4x8 M03509 5 8 Cap PVC grey O M01251 6 4 Rubber foot round M03582 7 1 Lower part of housing F03952 8 1 Holding device for carrying handle M03562 9 1 Handle F03957 10 5 Rubber foot ee M01121 11 1 Mains cable E03683 8 26 Revision 1 Spare parts soyer 8 2 Exploded view of BMS 8N stud welder Overview Z 0174 X 8 27 Revision 1 Spare parts soyer 8 3 Spare parts list for BMS 8N stud welder View A 8 28 Item No LO OO JO Un P OO 4 k Quantity Description ee BRP D kA D A k kA kA k k kA kA k k P kA k kA kA D A k kA kA k k kA P HPP Hr Rubber mat Spacing bolt M4x10 Spring ring M4 Busbar Hexagon head cap screw M8x16 Spring ring M5 Hexagon head cap screw M5x12 Cable harness 160 mm Spring ring M8 Hexagon nut M8 Flat cable 26 pole Synthetic nut M4 Busbar Thyristor clamping cap Thyristor S30E4A Hexagon nut M8 Spring ring M8 Hexagon head cap screw M8x16 Diode SKR 130 16 Toroidal core coated Spring ring M5 Hexagon head cap screw M5x12 Thyristor mounting plate Capacitor 22000uF Rubber mat Order No F03951 F03949 M03553 M01074 M01012 F04295 FA E01897 E01892 03535 F02226 M01129 M01075 M01117 F03947 FA E M01077 M01015 F03851 FA E M03538 F04297 E01987 E01361 M01015 M01077 F03947 FA E M01129 E01203 E03607 M01075 M01117 F03593 E0119
42. ursuant to other laws which serve to implement EC Directives other than the aforementioned Council Directive This Confirmation of Conformity only relates to the sample submitted for testing or to the technical report Datum der Best tigung Date ofcertificate 28 Juli 1999 LGA EMV Fachzertifizierer Zertifizierungsstelle Produkte EMV e Es Dr Ing E Zeitler Dipl Ing FH E nger KON22288 D0C DVS TIERT o V ner Str 172 D 40223 D sseldorf Heinz Soyer nschwei technik GmbH Inninger Stra e 14 82237 W rthsee Etterschlag ed a quality system in the following areas of Adr application ent Production and Sales of Stud Welding A Equipment Production of Welding Studs G a quality audit it was proved that this quality stem has been put into service and fulfils the f requirements of the Standard _ DIN EN ISO 9001 2000 station No DE 1996 001 2 First Certification 02 12 1996 09 19 2005 D sseldorf 09 19 2002 Certification Body CG INN 4 ER nd CL e au IS ing W Dipl Ing M Lehmann i soyer Contents Contents 1 General ___________LLLLL LLLLLLLLIN 1 1 1 1 The following should be principally observed _ 20 200000 ln 1 1 1 2 Application 1 2 1 3 Information on the product 0 20 0000 1 2 1 4 Type plate 000000000000 oo 1 2 1 5 Information on the documentation 2 22O 1 3 1 5 1 Chapters of operating instructions 1 3 1 5 2 Information on operating instructions e
43. ust never be exceeded 3 13Stopping the stud welder e e e Switch off the mains switch chapter 5 1 item 9 located at the stud welder s rear side Disconnect the mains plug from the socket Disconnect the earth cables chapter 5 1 item 5 the control cable chapter 5 1 item 7 the welding cable chapter 5 1 item 6 from the stud welder Roll up the cables without buckling them LS Our tool and gear wagon GW 1 is the optimum solution for installing SOYER stud welders and for properly storing welding pistols cables studs retrofit kits etc 3 14The S symbol Make sure stud welder cannot be used by unauthorized persons Check the welding cable and connections of the stud welder for damage such as burn off mechanical wear etc and have damaged parts replaced by SOYER customer service 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 3 14 Revision 1 soyer Installation of stud welder 4 Installation of stud welder e Only install the stud welder on an even surface The four anti vibration pads located on the bottom of the stud welder guarantee its anti skid position and serve as vibration dampers e Although the stud welder is resistant to environmental influences
44. y 89 392 EEC annex IIA Producer Declaration Designation of machine Machine type Machine no Applicable EC directives Applied harmonised standards in particular Applied national standards and technical specifications in particular Date Producer s signature Signer s function Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger Stra e 14 D 82237 W rthsee We herewith declare that the machine described in the following and the version available on the market correspond in design and construction to the fundamental safety and health requirements stipulated by the EC Directive on Machinery Any modification of this machine without confirmation shall automatically annul this declaration Stud welder with tip ignition BMS 8N EC Directive on Machinery 89 392 EEC in the version 91 368 EEC EC Directive on Low Voltage 73 23 EEC EC Directive on Electromagnetic Compatibility 89 336 EEC in the version 93 31 EEC EN 292 1 and EN 292 2 EN 60 204 1 EN 60 974 1 VBG 1 VBG 5 VDE 0544 December 1 1997 Technical Management LGAM Landesgewerbeanstalt Bayern EG KON FORMITATSBESTATIGU NG im Rahmen der unten aufgef hrten Normen EC CONFIRMATION OF CONFORMITY on electromagnetic compatibility according the standards mentioned below ber die elektromagnetische Vertr glichkeit Zertifikat Nr Certificate No EMA 299 2288 Pr fstelle EMV Pr fzentrum
45. ys item 4 chapter 5 1 on the front panel of the stud welder shortly light up after switching the stud welder on e Select charging voltage by means of function key Arrow up item 1 chapter 5 1 or Arrow down item 3 chapter 5 1 depending on the re spective stud diameter e Position pistol with welding stud on the workpiece When earth connection is made and the stud in the pistol touches the workpiece the LED Stud on workpiece item 4 4 chapter 5 1 2 lights up e Press pistol switch LED Release item 4 3 chapter 5 1 2 lights up and welding process is released Note regarding stud welding pistol PS 1 Pull the trigger handle of the stud welding pistol PS 1 rapidly to be sure to release a welding process Please also observe chapter 9 2 Troubleshooting Hold the pistol still during the welding process and wait until the welding process has been completed before removing it vertically from the welded stud A possible operating error e g the welding pistol glides off during welding is identified by the stud welder and indicated as failure by LED Malfunction item 4 1 chapter 5 1 2 lighting up also refer to chapter 9 1 Error code After removing the welding pistol from the welded stud the capacitor battery is recharged The stud welder is ready for welding again after a few seconds LED Ready item 4 2 chapter 5 1 2 lights up 5 4 Welding parameters The welding parameters of the stud we
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