Subscribe to Our Youtube Channel
Related Manuals for Soyer SK-5AP
Summary of Contents for Soyer SK-5AP
- Page 1 Operating Instructions Stud Welding Head SK-5AP | SK-5AP/KS GB: English version Read these operating instructions before starting any work! Doc.ID: P00268 Date of issue: 07.2024 www.soyer.com...
- Page 2 Notes for easier understanding of the operating instructions The term "stud welding head" in these operating instructions means the SK-5AP and/or SK-5AP/KS stud welding head. Complex stud welding systems generally have multiple welding heads. For better readability, product names are used in the singular even when referring to more than one product.
- Page 3 SK-5AP Stud welding head SK-5AP/KS Operating instructions Document no.: P00268 07-2024, translation of the original German instructions (German: P00168) All information contained in this document is the property of Heinz Soyer Bolzenschweißtechnik GmbH. Revision status Document created/amended Editor Date Original...
-
Page 4: Table Of Contents
SK-5AP stud welding head ....................23 6.3.1 Technical data for the SK-5AP stud welding head ............23 6.3.2 Admissible stud welding devices for SK-5AP stud welding head ........24 SK-5AP/KS stud welding head..................... 25 6.4.1 Technical data for the SK-5AP/KS stud welding head ............ 25 6.4.2... - Page 5 Information about connecting the earth cable ..............46 Start-up / Set-up of stud welding head ................48 Setting the immersion depth & lifting height of the SK-5AP / SK-5AP/KS welding head..48 9.1.1 Automatically setting the depth of immersion ..............48 9.1.2...
-
Page 6: General Information
Validity of the operating instructions These operating instructions apply to the following devices: Stud welding head SK-5AP Stud welding head SK-5AP/KS Registered trademarks The following terms in these instructions are used with registered trademarks: SOYER Developments/technologies of Soyer GmbH. ® Soyer Bolzenschweißtechnik Operating instructions... -
Page 7: Declaration Of Incorporation
EC Machinery Directive (2006/42/EC). Please note that significant changes to the device will cause the declaration of incorporation to become void. Furthermore, the manufacturer's warranty may be rendered invalid. Soyer Bolzenschweißtechnik Operating instructions... - Page 8 Soyer Bolzenschweißtechnik Operating instructions...
-
Page 9: Manufacturer
Manufacturer The manufacturer of the devices is: Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 82237 Wörthsee Tel.: 0049-8153-885-0 Fax: 0049-8153-8030 Mail: info@soyer.de Web: www.soyer.de, www.soyer.com Instruction, training ® SOYER offers optional and individual instruction in the operation of the devices. -
Page 10: Important Safety Instructions
Do not touch the surface or the housing: shock hazard. Do not touch or open, danger to unauthorised persons. Danger to persons with medical implants such as pacemakers. The information sign is not a warning sign. It indicates important and useful information on the subject. Soyer Bolzenschweißtechnik Operating instructions... -
Page 11: General Safety Instructions
Before performing any work on the device, the mains switch of the device • must be turned off and the mains plug must be disconnected. • Before performing any work on the device, the supply cables to the device must be disconnected. Soyer Bolzenschweißtechnik Operating instructions... - Page 12 If light curtains are used as protection devices, they must be firmly fixed to • the floor at a distance from the system defined by the manufacturer. Soyer Bolzenschweißtechnik Operating instructions...
- Page 13 Operation site Danger of explosion from an inappropriate installation location in explosive atmospheres The devices are not designed for use in explosive zones. The devices must not be installed and operated in explosive • atmospheres. Soyer Bolzenschweißtechnik Operating instructions...
- Page 14 Danger of fire from hot welding spatter Welding spatter and hot workpieces resulting from the welding process may represent a danger of fire. Do not store combustible or highly flammable materials in the welding area. • Soyer Bolzenschweißtechnik Operating instructions...
- Page 15 Danger from pneumatic hoses Loose pneumatic hoses may whip about when pressurised and thus pose a danger. Always secure pneumatic hoses to the hose clamps provided. • Regularly check that the pneumatic hoses are secure and undamaged. • Soyer Bolzenschweißtechnik Operating instructions...
-
Page 16: Personal Protective Equipment
Wear appropriate, non-flammable, heat- resistant protective gloves. Protective clothing Welding spatters occur during the welding process. Wear appropriate, non-flammable and, if necessary, heat-resistant protective clothing. Soyer Bolzenschweißtechnik Operating instructions... -
Page 17: Intended Use
With the SOYER stud welding head SK-5AP and/or SK-5AP/KS, pins and threaded ® studs from M3 to M8 as well as many different weld fasteners made of steel, stainless... -
Page 18: Incorrect Use
2.4.1 Incorrect use Any use of the devices deviating from the intended use is considered as not intended. If in any doubt, ask SOYER whether the planned use is permissible. ® Not intended use, unauthorised modification, separate device operation or manipulation of one or multiple devices will void the declaration of conformity and warranty claims against the manufacturer. -
Page 19: Transport
Work on live elements may only be performed by authorised electricians. This work must be performed in accordance with the applicable technical rules for electrotechnical devices. All devices of Soyer Bolzenschweißtechnik GmbH may only be opened by SOYER personnel or personnel authorised by SOYER ®... -
Page 20: Description Of Stud Welding Head
Figure 01: SK-5AP/KS stud welding head Item Designation SK-5AP stud welding head, with gap welding procedure. SK-5AP/KS stud welding head, with contact and gap welding procedure (switchable). General description The stud welding head is designed for stationary installation on systems and machines or on a robot. -
Page 21: Distance Measuring System
The measured values can be transferred to an external control unit for evaluation (quality control) via an interface. The distance measuring system requires an external power supply. Figure 02: SK-5AP stud welding head Item Designation Connection for power supply and data transmission... -
Page 22: Different Welding Methods
Different welding methods The following welding methods are possible with the SK-5AP and/or SK-5AP/KS SOYER stud welding head: ® Capacitor discharge stud welding • • welding (stud welding in a radial symmetrical magnetic field) ® Short-cycle drawn arc welding •... -
Page 23: 5Ap Stud Welding Head
SK-5AP stud welding head Figure 03: Dimensions of SK-5AP stud welding head Note on the serial number! The serial number is engraved on the left & right-hand side of the housing. 6.3.1 Technical data for the SK-5AP stud welding head... -
Page 24: Admissible Stud Welding Devices For Sk-5Ap Stud Welding Head
6.3.2 Admissible stud welding devices for SK-5AP stud welding head Stud welding device Note BMS-10P Standard device BMS-9 Automatik HesoMatic-9 BMK-16i Automatik Soyer Bolzenschweißtechnik Operating instructions... -
Page 25: 5Ap/Ks Stud Welding Head
SK-5AP/KS stud welding head Figure 04: Dimensions of SK-5AP/KS stud welding head Note on the serial number! The serial number is engraved on the right-hand side of the housing. 6.4.1 Technical data for the SK-5AP/KS stud welding head Designation SK-5AP/KS stud welding head Item no. -
Page 26: Admissible Stud Welding Device For Sk-5Ap/Ks
BMS-10P year of manufacture) GAP/CONTACT switchover The SK-5AP/KS stud welding head can be switched for gap or contact welding using the adjusting ring on the welding head. A time-consuming conversion or welding head change is therefore no longer necessary. Contact welding is preferably used for stud welding on problematic surfaces. -
Page 27: Connection And Installation
Connection and installation The stud welding head is already integrated into a SOYER ® stud welding system in the factory. This is the best solution. You are using a perfectly coordinated stud welding system. Observe the following instructions, particularly in combination with a robot or an external handling system (special system). -
Page 28: Pneumatic Slide
Pneumatic slide In the following, we explain the assembly using the example of a SOYER pneumatic ® slide with 125 mm lift and a stud welding head. Figure 05: Mounting example with pneumatic slide Item Designation SK-5AP/KS stud welding head... -
Page 29: Aligning The Welding Head
Push the adjusting mandrel (b) into the stud welding head (a) until the stop. Pay attention to the installation position (guide pin) of the adjusting mandrel. Then, fix the adjusting mandrel in place with the union nut (c). Soyer Bolzenschweißtechnik Operating instructions... - Page 30 Step 9: Remove the adjusting mandrel and insert a suitable stud chuck and stud feed pipe again, as set out in chapter „7.2 Inserting the stud chuck and stud feed pipe“ from page 39. Alignment is complete. Soyer Bolzenschweißtechnik Operating instructions...
-
Page 31: Compressed Air Connection
A hose package is not included in the scope of delivery. This must be ordered separately. Tension relief! The quick couplings and connectors are not suitable for tension relief. Ensure sufficient tension relief and secure cable routing for robot applications, for example. Soyer Bolzenschweißtechnik Operating instructions... -
Page 32: Feed Unit Connections
If the stud feed hose is used incorrectly, or an unsuitable hose is used, there is a risk of injury due to ejected welding studs. Only use original stud feed hoses from Soyer GmbH. • Only ever use stud feed hoses which match the stud diameter. -
Page 33: Inserting The Stud Feed Hose
If the stud feed hose is used incorrectly, or an unsuitable hose is used, there is a risk of injury due to ejected welding studs. • Only use original stud feed hoses from Soyer GmbH. Only ever use stud feed hoses which match the stud diameter. •... - Page 34 Manually rotate the union nut (a) onto the stud feed pipe (b) until the stop. The assembly is complete. Insert the stud feed pipe into the welding head as described in chapter “7.2 Inserting the stud chuck and stud feed pipe” on page 39. Soyer Bolzenschweißtechnik Operating instructions...
- Page 35 For this reason: To avoid damage to the clamp of the stud feed pipe in the welding head, it is recommended to always remove the stud feed pipe from the welding head when changing the hose. Soyer Bolzenschweißtechnik Operating instructions...
-
Page 36: Connections On The Sk-5Ap And/Or Sk-5Ap/Ks Stud Welding Head
6.10.2 Connections on the SK-5AP and/or SK-5AP/KS stud welding head Figure 06: Connections on the SK-5AP and/or SK-5AP/KS stud welding head Top view Item Designation Mains supply connection Connection of EQS-3 quality assurance unit (optional) Welding cable connection Air connection "backward"... -
Page 37: Description Of The Automatic Stud Chuck
Stud chucks are wear and tear parts. To avoid downtimes, we recommend that you keep sufficient stocks of the required dimensions. Please also refer to chapter “15.1 Spare and conversion parts for stud welding head and stud chuck” on page 63. Soyer Bolzenschweißtechnik Operating instructions... -
Page 38: Adjusting The Stud Chuck
1.5 mm and 3 mm above the stud chuck with its flange upper edge. Step 4: Place a distance sleeve or filling distance part combination between the plunger and the stud chuck. The adjustment is complete. Soyer Bolzenschweißtechnik Operating instructions... -
Page 39: Inserting The Stud Chuck And Stud Feed Pipe
Please also refer to chapter “6.10 Inserting the stud feed hose” on page 33, which describes how the stud feed hose is inserted into the stud feed pipe. The stud welding head is usually supplied together with a SOYER CNC coordinate ®... - Page 40 If not, the stud must either be moved into this position manually or the welding head must be hit with compressed air for the plunger to push the stud and position it. The assembly is complete. Soyer Bolzenschweißtechnik Operating instructions...
-
Page 41: Connecting The Stud Welding Head
8 Connecting the stud welding head The following describes how the devices are connected to a SOYER CNC coordinate ® bench welding machine, for example, and how they are interconnected. Connection diagram (example) Figure 08: Connection diagram Item Designation Colour legend... -
Page 42: Connection Diagram - Stud Welding Head With Bms-10P
Connection diagram – Stud welding head with BMS-10P Figure 09: Connection diagram - Stud welding head with BMS-10P Connection diagram – Stud welding head with BMS-10P and EQS-3 Figure 10: Connection diagram - Stud welding head with BMS-10P and EQS-3 Soyer Bolzenschweißtechnik Operating instructions... -
Page 43: Connections On The Bms/Bmk Stud Welding Device
The following describes how to connect to a BMS device. The connection process is the same for all BMS and BMK devices. For BMK devices, the gas and SRM lines also need to be connected. ® Soyer Bolzenschweißtechnik Operating instructions... - Page 44 (b = mains cable). Step 2: Earth connection Plug the earth cable connected to the workpiece into the sockets (a) and turn the plugs to the right up to the stop. Soyer Bolzenschweißtechnik Operating instructions...
- Page 45 Take note of the labelling on the connection and hose, do not mix Gas and SRM connection (only for BMK devices!) Step 4: ® Connect the gas (a) and SRM (b) lines. ® The front panel of the device is connected. Soyer Bolzenschweißtechnik Operating instructions...
-
Page 46: Information About Connecting The Earth Cable
This also includes stud welding on vertical sections. In order to achieve good welding results, carry out several welding test runs under different conditions. Simply change the position of the earth clamps, for example. Soyer Bolzenschweißtechnik Operating instructions... - Page 47 Ideally, the stud is located in the centre of the two earth connections. Asymmetrical earth connection The arc is deflected to the side where there is a lower current density. Workpiece geometry Additional workpiece masses disturb the arc symmetry. Soyer Bolzenschweißtechnik Operating instructions...
-
Page 48: Start-Up / Set-Up Of Stud Welding Head
The height of lift always depends on the respective stud dimension and welding task. With the SK-5AP and/or SK-5AP/KS stud welding head, the stud must be lifted to a defined height directly before the welding process and lowered again during the welding process. -
Page 49: Manually Setting The Depth Of Immersion
Check whether there is a stud in the stud chuck. If necessary, reload a stud by pressing the release button (see chapter ”6.10.2 Connections on the SK-5AP and/or SK-5AP/KS stud welding head” on page 36) on the stud welding head. - Page 50 (b). The immersion depth is not set properly. The weld stud (a) cannot immerse into the workpiece (b). The immersion depth is not set properly. The stud chuck (a) without weld stud touches the workpiece (b). Soyer Bolzenschweißtechnik Operating instructions...
-
Page 51: Adjusting The Height Of Lift
Setting the height of lift in the setting mode The height of lift must be set for the SK-5AP and/or SK-5AP/KS stud welding head (GAP operating mode). The stud is lifted to a defined height/to a defined time directly before the welding process and automatically lowered again during the welding process. - Page 52 Usually, the stud welding head is moved to the welding position by means of a pneumatic slide. Step 7: Check if the welding stud touches the workpiece (stud is seated on the workpiece). Soyer Bolzenschweißtechnik Operating instructions...
- Page 53 For further reference values for the correct height of lift or lift time, please refer to the respective device instructions. The adjustment can be repeated as often as needed. To prevent the magnetic coil from overheating, however, it is necessary to wait for approx. one second between two test lifts. Soyer Bolzenschweißtechnik Operating instructions...
-
Page 54: Check The Automatic System Before Starting
In this case, immediately contact the responsible department manager or the responsible department to carry out the necessary repairs or maintenance works. Personal protective equipment (PPE) Use the personal protective equipment (e.g. hearing protection, glare protection, safety footwear, etc.) prescribed by the operating company. Soyer Bolzenschweißtechnik Operating instructions... - Page 55 Check that there are no objects within the range of motion of the linear axes. Check that all precautions have been taken to ensure that no unauthorised persons or persons without PPE come close to the system while it is in operation. Soyer Bolzenschweißtechnik Operating instructions...
-
Page 56: Welding Operation
• 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. With automatic operation, ensure tight fit of the stud feed hose. - Page 57 Before using the stud welding equipment, please also refer to chapter “2 Important safety instructions” on page 10. • Please observe all safety measures prescribed by the operating company. • If you have any problems understanding the operating instructions, contact the manufacturer, Soyer GmbH. Soyer Bolzenschweißtechnik Operating instructions...
-
Page 58: Notes On Checking The Quality Of The Weld
The welding bead is weak and unevenly formed. Poor welding joint, e.g. due to a blow effect or a welding gun that was shaken or applied at a slant. The stud flange is not welded completely and has visible imperfections. Undercuts are visible. Soyer Bolzenschweißtechnik Operating instructions... -
Page 59: Welding Defects And Their Causes
11.2 Welding defects and their causes In the following, the most common welding errors, possible causes and troubleshooting are described. Please contact Heinz Soyer Bolzenschweißtechnik GmbH if a problem cannot be solved. Error Possible cause and troubleshooting Device does not Stud welding device is not switched on. -
Page 60: Malfunctions With An Error Message
11.3 Malfunctions with an error message Dangers during troubleshooting During troubleshooting, various dangers may occur. All devices of Soyer Bolzenschweißtechnik GmbH must only be opened by • SOYER personnel or personnel authorised by SOYER ® ® For troubleshooting, the device must be disconnected from the power supply •... -
Page 61: Maintenance And Repair
Wear and tear parts such as stud chucks, gas shroud, support tube, plunger and stud feed pipe must be replaced when worn out. Repair of the devices and their modules may only be performed by Heinz Soyer Bolzenschweißtechnik GmbH or authorised specialists. -
Page 62: Service
Tel.: 0049-8153-885-0 Fax: 0049-8153-8030 Mail: info@soyer.de Please have the serial number ready during service requests. agent. Contact information Alternatively, you can also contact your respective SOYER ® can be found on our website at www.soyer.de or www.soyer.com (English) 14 Warranty conditions The warranty period for commercial use in single-shift operation or equivalent is 12 months. -
Page 63: Spare And Conversion Parts
Ø 7.1 mm 1 x 17 mm Stud feed hose (always F01081 cut by metre. Please F01082 state desired length in metres). Item quantity 1 F01083 means 1 m. F01084 M8 / Ø 7.1 mm F01085 Soyer Bolzenschweißtechnik Operating instructions... - Page 64 M5 x 6 mm F04865 studs M6 x 8 mm F04866 Ø 7.1 x 10 mm F04867 M8 x 10 mm * Availability on request Auxiliaries / Tools Description Dimension Item no. Adjusting mandrel for F07171 stud welding head Soyer Bolzenschweißtechnik Operating instructions...
- Page 65 Soyer Bolzenschweißtechnik Operating instructions...
- Page 66 Soyer Bolzenschweißtechnik Operating instructions...
- Page 67 Soyer Bolzenschweißtechnik Operating instructions...
- Page 68 Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 82237 Wörthsee Tel.: 0049-8153-885-0 Mail: info@soyer.de www.soyer.de...
Need help?
Do you have a question about the SK-5AP and is the answer not in the manual?
Questions and answers