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Welding operation

54

 Operating Instructions Soyer Bolzenschweißtechnik

14.5 Malfunctions with an error message

When there is a stud welding device malfunction, an error message (code) ap-
pears on the display.

DANGER

!

Dangers during troubleshooting

During troubleshooting, various dangers may occur.

• All devices of Soyer Bolzenschweißtechnik GmbH may only be opened by 

personnel of Soyer or personnel authorised by Soyer.

• For troubleshooting, the device must be disconnected from the main power 

supply and secured against accidental switch-on.

Error 

code

Description

Possible cause

E01

Safety shutdown as a voltage of more 
than 25 V was measured for more 
than approx. 40 ms on the welding 
power sockets.

• Stud inserted too deep into the stud chuck
• Mechanical problems with the gap welding gun
• External voltage of other welding devices
• Error in the device (thyristor short circuit)

E02

Error when charging the capacitors

• Welding capacitors faulty (leakage current)
• Charging current source faulty

Содержание BMS-8N

Страница 1: ...EN Operating Instructions Stud welding devices BMS 8N BMS 8NV Stud welding guns PS 1 and PS 1K PS 3K Stativ PS 0K...

Страница 2: ...no P00198 10 2018 translation of the original instructions English P00298 All information in this document is the property of Heinz Soyer Bolzenschwei technik GmbH Device Type Serial number Stud weldi...

Страница 3: ...ect use 14 2 5 Intended use of the stud welding guns 14 2 5 1 Incorrect use 14 2 6 Operating company prerequisites 15 2 6 1 Prerequisites for personnel 15 3 Transport 16 4 Storage shutdown 16 5 Dispos...

Страница 4: ...tud welding gun 36 10 2 Cleaning of the stud welding gun 37 11 Description of the stud chuck 38 11 1 Adjusting adjustable stud chucks 38 11 2 Installing the stud chuck gun without support 39 11 3 Inst...

Страница 5: ...Soyer Bolzenschwei technik 5 CONTENTS 14 3 Switching off the device 52 14 4 Welding defects and their causes 53 14 5 Malfunctions with an error message 54 15 Maintenance and repair 56 16 Service 56 17...

Страница 6: ...to help you recognise any possible residual risks and prevent hazards The drawings and illustrations in these operating instructions are for illustrative purposes and may vary slightly from the actua...

Страница 7: ...irements of the stated guidelines and standards Any modification of this machine without confirmation shall automatically annul this declaration Designation of the machine Machine type Machine no Appl...

Страница 8: ...ormation on the scope and costs of instruction and training can be obtained from Soyer GmbH 1 5 Standards and directives The following standards inter alia must be observed for carrying out stud weldi...

Страница 9: ...s used in this manual This warning sign indicates imminent danger lead ing to severe injuries or death This warning sign indicates a potentially dangerous situation that may lead to severe injuries or...

Страница 10: ...re is a danger to life from electric current Work on electric or electronic components may only be performed by trained electrotechnical personnel in accordance with currently applicable electrotechni...

Страница 11: ...evice must be disconnected If protection devices have to be removed for maintenance work the device may only be switched on again when all protection devices are installed and their functionality has...

Страница 12: ...ctive equipment Before working on hot parts of the device check if they have cooled down WARNING WARNING Danger of burns from hot welding spatters During the welding process dangerous welding spatters...

Страница 13: ...serve the following instructions for protective equipment Recommended personal protective equipment Safety goggles Welding spatters and a flash occur during the welding pro cess In order to protect yo...

Страница 14: ...y and warranty claims against the manufacturer 2 5 Intended use of the stud welding guns With the SOYER stud welding guns pins and threaded studs from M3 to M8 up to M10 with special gun and adapter a...

Страница 15: ...and trained accordingly They must have read and understood these operating in structions When working on the device they must also be able to avert possible residual danger to themselves or third par...

Страница 16: ...e shutdown During storage or shutdown make sure to protect the device against dirt and humidity Protect the device against unauthorised access by third parties 5 Disposal Local environmental directive...

Страница 17: ...d in accordance with DIN EN ISO 13918 capacitor discharge Welding of weld fasteners made of aluminium and brass is also possible 6 2 1 Product features Patented charging circuit Pat No 199 15 396 5 al...

Страница 18: ...ional principle The stud tip is placed into contact with the work piece The ignited arc creates a melt zone on the stud and the metal sheet The stud is immersed in the weld pool The material solidifie...

Страница 19: ...voltage or the stud diameter c Up arrow key to decrease the charging voltage or the stud diameter depending on the display settings d Display of operating states see chapter 6 3 2 Displaying the oper...

Страница 20: ...8N V stud welding devices 20 Operating Instructions Soyer Bolzenschwei technik Figure 2 Overview of the back panel Item Designation a Mains switch for turning the device on off b Fuses c Type plate d...

Страница 21: ...ixed to the stud diameter and cannot be changed when displaying the stud diameter For adjusting the charging voltage switch to the display of the charging voltage See chapter 13 1 Adjusting the chargi...

Страница 22: ...s up when the stud welding device is ready for operation in normal mode b Stud on workpiece The LED lights up when the earth terminal is connected and the stud touches the workpiece c Release The LED...

Страница 23: ...ire ments BMS 8NV M10 with special welding gun Power source Capacitor bank 66 000 F Option for BMS 8NV 99 000 F Charging voltage 50 200 V infinitely variable up down Welding sequence BMS 8N 3 mm up to...

Страница 24: ...o wrong gun Hazards for the operator may occur when a wrong welding gun is used Only use welding guns hereinafter permitted by Soyer i The use of other guns or guns from another manufacturer will inva...

Страница 25: ...mproper cleaning of the stud welding device can endanger personnel The device may only be cleaned by trained specialists Before any cleaning work is done the stud welding device must be discon nected...

Страница 26: ...in the gun the stud of this gun is pressed firmly to the workpiece contact gun The stud is not lifted before welding Item Designation a PS 0K stud welding gun contact gun without lifting magnet b Sup...

Страница 27: ...g gun Designation PS 0K stud welding gun contact gun Item no P02102 Welding procedure Capacitor discharge stud welding Stud diameter M3 M8 Stud chuck Adjustable Stud length Adjustable stud chuck up to...

Страница 28: ...e support tube using a suitable tool The frequency of cleaning depends on the operating conditions of the stud welding gun CAUTION CAUTION Risk of injury during cleaning Welding spatters and slag can...

Страница 29: ...ribed or centre marked surfaces without requiring any auxiliary devices The spring pressure is adjustable in order to ensure optimal welding re sults The stud is not lifted before welding Item Designa...

Страница 30: ...no P02110 Welding procedure Capacitor discharge stud welding Stud diameter M3 M8 Stud chuck Adjustable Stud length Adjustable stud chuck up to a maximum of 35 mm Longer stud lengths with optional acce...

Страница 31: ...the gun legs using a suitable tool The frequency of cleaning depends on the operating conditions of the stud welding gun CAUTION CAUTION Risk of injury during cleaning Welding spatters and slag can b...

Страница 32: ...ing in the gun the stud of this gun is pressed firmly to the workpiece contact gun The stud is not lifted before welding Item Designation a PS 1K stud welding gun contact gun without lifting magnet b...

Страница 33: ...ud welding gun contact gun Item no P02117 Welding procedure Capacitor discharge stud welding Stud diameter M3 M8 Stud chuck Adjustable Stud length Adjustable stud chuck up to a maximum of 35 mm Longer...

Страница 34: ...the support tube using a suitable tool The frequency of cleaning depends on the operating conditions of the stud welding gun CAUTION CAUTION Risk of injury during cleaning Welding spatters and slag ca...

Страница 35: ...stud welding guns Due to a projection on the gun legs and a spring in the gun the stud of this gun is pressed firmly to the workpiece contact gun The stud is not lifted before welding Item Designatio...

Страница 36: ...e PS 3K Stativ stud welding gun Designation Stud welding gun PS 3K contact gun PS 3K Stativ Item no PS 3K P02131 PS 3K Stativ P02143 Welding procedure Capacitor discharge stud welding Stud diameter PS...

Страница 37: ...un and the gun legs support using a suitable tool The frequency of cleaning depends on the operating conditions of the stud welding gun CAUTION CAUTION Risk of injury during cleaning Welding spatters...

Страница 38: ...bed in these instructions 11 1 Adjusting adjustable stud chucks Adjustable stud chucks must be adjusted to the length of the welding stud and if necessary to the gun size The standard stud chuck can h...

Страница 39: ...o that the top of the flange of the stud sits between 1 5 mm and 3 mm above the stud chuck when it touches the screw Step 4 Fix the stop screw with the lock nut The adjustment is complete Adjusting an...

Страница 40: ...Step 4 Undo the union nut Step 5 If there is still a stud chuck in the gun remove it Step 6 Slide the stud chuck up to the stop into the spring piston of the gun Step 7 Hand tighten the union nut Step...

Страница 41: ...n The stud stud flange must protrude 1 5 3 mm from the support tube If applicable correct the setting of the stud chuck see chapter Adjusting the stud chuck on page 38 The assembly is complete Install...

Страница 42: ...ighten the union nut b Step 6 Insert a stud and check the stud protrusion The stud stud flange must protrude 1 5 3 mm from the support tube If applicable correct the settings of the stud chuck by movi...

Страница 43: ...ation and workplace must comply with legal requirements Ensure that the installation location has a good accessibility for maintenance work Make sure that the stud welding device cannot be soiled by d...

Страница 44: ...positioned in the centre of the connecting line of the two earth clamps This guarantees a symmetrical current distribution around the stud as well as good welding results Difficult areas are weldings...

Страница 45: ...r workpiece geometry Blow effect Explanation Symmetrical earth connection Ideal condition stud is located in the centre of the two earth connections Asymmetrical earth connection The arc is deflected...

Страница 46: ...he manufacturer See chapter 6 5 Per mitted stud welding guns on page 24 Plug the welding cable into the socket a and turn the plug to the right up to the stop Plug the control cable into the control c...

Страница 47: ...e workpiece Thickness of the workpiece Material of the welding stud Diameter of the welding stud With the arrow keys on the display the charging voltage or the stud diameter can be adjusted The chargi...

Страница 48: ...e device as described in chapter 12 2 Connection of the stud welding device and the stud welding guns on page 44 Step 2 Either select the required stud diameter or the required charging voltage for sw...

Страница 49: ...the operating instructions contact the manufacturer Soyer Carrying out welding Step 1 WARNING WARNING Before welding see chapter 2 Important safety instruc tions on page 9 Step 2 Connect the gun to th...

Страница 50: ...r Technical Bulletin DVS 0904 Instruction for practice Arc stud welding 14 2 1 Visual inspection The visual inspection serves as a rough check for major defects The uniformity of the weld is assessed...

Страница 51: ...the immersion dis tance lift is too small The stud is constricted to the welding joint The stud is only partially welded Poor welding joint e g because the weld ing energy is too low or the lift is to...

Страница 52: ...lzenschwei technik 14 3 Switching off the device Switch off the stud welding device at the mains switch The connected welding gun is switched off automatically Ensure that the stud welding device can...

Страница 53: ...ates on page 22 Prepare the workpiece or stud Grind connection points to a bright metal finish Scorched stud thread Stud is too loose in the stud chuck Press or retighten the stud chuck Stud chuck is...

Страница 54: ...nnel authorised by Soyer For troubleshooting the device must be disconnected from the main power supply and secured against accidental switch on Error code Description Possible cause E01 Safety shutdo...

Страница 55: ...charging resistor Safety relay is clamping or sticking Switching times of the safety relay too long E04 Incorrect mains voltage The mains voltage must be between 90 130 V at 60 Hz or 180 275 V at 50 H...

Страница 56: ...nik GmbH or authorised spe cialists 16 Service If servicing is required please contact Heinz Soyer Bolzenschwei technik GmbH Inninger Stra e 14 82237 W rthsee Phone 0049 8153 885 0 Fax 0049 8153 8030...

Страница 57: ...he Etterschlag plant Wearing parts are excluded The warranty claim shall expire if damage is caused through improper operation repairs or interventions are undertaken by unauthorised persons and acces...

Страница 58: ...Heinz Soyer Bolzenschwei technik GmbH Inninger Stra e 14 82237 W rthsee Tel 0049 8153 885 0 Mail info soyer de...

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