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Summary of Contents for Soyer SK-5AN
- Page 1 Welding Head Operating Instructions SK-5AN SK-5AP GB: English Version Read these operating instructions before starting any work! Doc.ID: P00251 Date of issue: 05.2013 www.soyer.de...
- Page 3 * Please enter the serial number here, so that the data is immediately available if you need service support Heinz Soyer Bolzenschweißtechnik GmbH www.soyer.de Inninger Straße 14 | 82237 Wörthsee | Tel.: +49 8153 8850 | Fax: +49 8153 8030 | E-Mail: info@soyer.de |...
- Page 4 ___________________________________________________________________________________________________ Thank you! We congratulate you on purchasing your SOYER stud welding head. You have made an excellent choice. Your SOYER stud welding head was especially developed for fastening SOYER welding studs as per DIN EN ISO 13918 on metallic workpieces at lightning speed.
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Page 6: Table Of Contents
Installation of stud chuck into welding head .................... 19 Adjusting the depth of immersion ......................20 4.3.1 Adjustment of immersion depth for SK-5AN welding head .............. 21 4.3.2 Adjustment of immersion depth for SK-5AP welding head .............. 23 Adjustment of the proximity switch ......................24 Adjusting the height of lift ........................ - Page 7 ___________________________________________________________________________________________________ List of standards and guidelines ......................37 Terms of warranty ............................. 37...
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Page 8: Safety Instructions
___________________________________________________________________________________________________ 1 Safety instructions These safety precautions are for your safety. General safety instructions Take part in a training programme. Read and follow all safety precautions listed below and all chapters of this manual before starting to weld. Non-compliance with the safety precautions can result in personal injuries or death. - Page 9 ___________________________________________________________________________________________________ Fumes and gases can cause damage to your health Fumes and suspended/floating particles may be generated during welding. Beware of fumes detrimental to health, particularly when using surface treated materials. Please also observe the safety regulations applicable for your country. Do not inhale fumes and gases.
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Page 10: Description Of Reference Signs In The Operating Instructions
___________________________________________________________________________________________________ Description of reference signs in the operating instructions The non-observance of safety instructions such as pictographs and warning words can cause damage to persons. The safety instructions of this operating manual describe the following: Safety instructions Danger! Immediate hazards which could result in serious personal injuries or loss of life. -
Page 11: Staff Qualification And Training
Prevent the stud welding equipment being operated by unauthorized personnel Check welding cable and connections of the stud welding equipment for damage such as burn-off, mechanical wear etc. and have damaged parts replaced by the SOYER customer service... -
Page 12: General
___________________________________________________________________________________________________ 2 General The following should be principally observed... With the SK-5AN/5AP welding head you have purchased a product which is state-of-the-art technology fully complies with the current safety requirements and ensures high performance. Before installing the welding head, please observe the following: ... -
Page 13: Information On Operating Instructions
All obligations of Heinz Soyer Bolzenschweißtechnik GmbH result from the respective contract of purchase. This contract also contains the complete and universally valid warranties. These contractual warranty terms are neither extended nor restricted by the implementation of these operating instructions. -
Page 14: Description Of Welding Head
___________________________________________________________________________________________________ 3 Description of welding head Welding process 3.1.1 Capacitor discharge Capacitor discharge welding allows threaded studs, pins, internally tapped bosses, insulating nails, flat plugs, special studs and special welding elements from 2 – 8 mm in diameter (in special cases up to Ø 10 mm) made of steel and CrNi steel to be welded on metallic workpieces. -
Page 15: Different Welding Methods
Gas mixture containing 82% Argon (Ar) and 18% carbon dioxide (CO SK-5AN/SK-5AP welding head The SK-5AN and SK-5AP welding heads are suitable for being operated with capacitor discharge, drawn arc and short-cycle drawn arc. The compact and lightweight SOYER welding heads have a patented semi- and fully automatic stud feed system (Pat. -
Page 16: Dimensions
___________________________________________________________________________________________________ Dimensions The SK-5AN and SK-5AP welding heads are designed in a handy and robust way and are easy to service. The illustrations below show the welding heads. SK-5AN welding head Dimension "A" Dimension "B" Slide, 75 mm lift 185 mm 195.5 mm... -
Page 17: Technical Data
195.5 mm Slide, 126 mm lift 225.5 mm 299 mm Technical data SK-5AN/SK-5AP welding head Ø 3 – 8 mm and 6 – 35 mm in length Welding range - Studs and pins Range of application Steel, stainless steel - conditionally aluminium and brass,... -
Page 18: Adjustment Of Welding Head
___________________________________________________________________________________________________ 4 Adjustment of welding head The welding head allows studs to be automatically fed through a stud feed tube directly into the stud chuck. The plunger in combination with a selection of distance sleeves serves as a limit stop for welding studs of different lengths. -
Page 19: Adjustment Of Stud Chuck
___________________________________________________________________________________________________ Adjustment of stud chuck Choose the appropriate conversion kit for the respective stud diameter. Insert weld stud into the opening of the stud chuck (ignition tip or stud flange must point in the direction of the collet chucks of the stud chuck). ... -
Page 20: Adjusting The Depth Of Immersion
___________________________________________________________________________________________________ Push stud feed tube (item 2, chapter 4.2) through the support retainer (item 4, chapter 4.2). Ensure correct positioning while doing so. Adjusting the depth of immersion MORTAL DANGER The stud welder must be switched off before adjusting the depth of immersion. ... -
Page 21: Adjustment Of Immersion Depth For Sk-5An Welding Head
___________________________________________________________________________________________________ 4.3.1 Adjustment of immersion depth for SK-5AN welding head Locking device for stud feed tube Counternut 15. Air connection "forward" Workpiece retainer Precision slide 16. Air connection "backward" Workpiece 10. Proximity switch 17. Welding cable connection Weld stud 11. Lifting cylinder 18. - Page 22 ___________________________________________________________________________________________________ Position welding head (item 13, chapter 4.3.1) with stud chuck (item 6, chapter 4.3.1) and weld stud (item 4, chapter 4.3.1) on the workpiece retainer (item 2, chapter 4.3.1). Move workpiece (item 3, chapter 4.3.1) sideways towards the weld stud (item 4, chapter 4.3.1). ...
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Page 23: Adjustment Of Immersion Depth For Sk-5Ap Welding Head
___________________________________________________________________________________________________ 4.3.2 Adjustment of immersion depth for SK-5AP welding head Locking device for feed tube Counternut 15. Air connection "forward" Workpiece retainer Precision slide 16. Air connection "backward" Workpiece 10. Proximity switch 17. Welding cable connection Welding stud 11. Lifting cylinder 18. -
Page 24: Adjustment Of The Proximity Switch
___________________________________________________________________________________________________ Connect SK-5AP welding head to power supply unit. Connect power-supply unit to a 230 V socket. Switch on power-supply unit of digital display. Roughly set final limit stop by means of the adjusting screw (item 7, chapter 4.3.1). The welding head (item 13, chapter 4.3.1) should not touch the workpiece retainer or table top when moving downwards. -
Page 25: Adjusting The Height Of Lift
___________________________________________________________________________________________________ Adjusting the height of lift The height of lift is the distance the stud is lifted from the workpiece during the welding process and which is required to ignite the arc. The height of lift always depends on the respective stud dimension and welding task. To set the lift, switch on the stud welder. -
Page 26: Adjusting The Speed Of The Lifting Cylinder
___________________________________________________________________________________________________ Adjusting the speed of the lifting cylinder If the welding head touches the workpiece with too much force when moving down, the ignition tip, especially in case of aluminium studs, may become deformed, thus negatively impairing the welding result. Two choker valves are mounted to the air connections of the lifting cylinder (item 11, chapter 4.3.1) to control the speed when the welding head is moving vertically. -
Page 27: Start-Up
___________________________________________________________________________________________________ 5 Start-up Installation of welding head into mounting device The welding head with pneumatic slide is usually supplied in operative condition together with a mounting device or a CNC bench welding machine. Connection of welding head to stud welder ... -
Page 28: Operation
Move welding head into welding position by supplying the air cylinder with compressed air. With SOYER bench welding machines this can be done by operating the two-hand release or with SOYER CNC bench welding machines by calling the welding program. -
Page 29: Quality Control (Stud Welding)
6 Quality control (stud welding) General Provided that the SOYER stud welding system is properly used and the materials are appropriately selected, the strength of the welded joint (weld zone) will always be stronger than that of the stud or base material. The following tests are carried out in general practice: ... -
Page 30: Test Execution
___________________________________________________________________________________________________ Test execution 6.3.1 Visual inspection The visual inspection serves as a rough check for major defects. The uniformity of the weld is assessed. Good welded joint. Optimum setting. Collar spattered for about 1 – 1.5 mm around the flange. Stud flange is completely welded. -
Page 31: Bend Test
___________________________________________________________________________________________________ 6.3.2 Bend test 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 are welded and bent by 30° using a tube slipped over the stud. -
Page 32: Production Of Samples
Note Numerous special accessories are available for optimally testing stud welded joints. BP-1 SOYER Bend Testing Device for non-destructive stud testing to support quality assurance procedures DMS-1 SOYER Torque Wrench for non-destructive stud testing to support quality assurance procedures For further information, please contact our parent company or the customer service responsible for your area or... -
Page 33: Maintenance
Please note: A special wrench is needed to perform work. CAUTION Disconnect the mains cable from the mains supply before replacing any components. Electric ® and electronic components may only be replaced by the SOYER customer service or by trained specialised personnel. DANGER TO HEALTH Before starting maintenance works, disconnect the shielding gas supply and compressed-air supply from the connections of the stud welding equipment. -
Page 34: Troubleshooting
The following list of errors, their causes and countermeasures is to help you deal with any immediate on-the- spot problems. If you still cannot eliminate the problem, please contact the SOYER customer service responsible for your area or Heinz Soyer Bolzenschweißtechnik GmbH. - Page 35 Connector plug or connector socket of stud welder is burnt down. Have connector plug or connector socket replaced by SOYER customer service. Earth clamps are not attached to the workpiece. Attach earth clamps.
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Page 36: Transport And Storage
You have used low-quality studs with inaccurate dimensions or poor surface finish. Only use SOYER welding studs. Welding energy, welding time and/or gas flow are not set correctly. Set welding energy and/or gas flow according to the operating instructions of your stud welder. - Page 37 We cannot guarantee the perfect function of the stud welding system and the quality of welded joints when non-Soyer welding studs are used.
- Page 38 ___________________________________________________________________________________________________ Heinz Soyer Bolzenschweißtechnik GmbH www.soyer.de Inninger Straße 14 | 82237 Wörthsee | Tel.: +49 8153 8850 | Fax: +49 8153 8030 | E-Mail: info@soyer.de |...
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