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Soyer BMK-10i Operating Instructions Manual Download Page 57

 

 

 

 

Operating manual Soyer Bolzenschweißtechnik 

57 

 
 

12  Settings 

 
The stud welding device and gun must be matched and adjusted for the respective 
processing. 
 
 

12.1  Setting the welding parameters 

 
How to set the welding parameters of the 
 
• Welding current 
• Welding time 
• SRM current 
• Gas preflow time and 
• Lift time/Height of lift 
 
is explained in the following. 

 

To achieve an optimum stud welding result, it is necessary to carry out some test 
welds with different settings. 
The parameters to be set on the stud welding device also depend on the following 
influencing factors: 
 
• Material of the workpiece 
• Thickness of the workpiece 
• Material of the welding stud 
• Diameter of the welding stud 
 
 

 

Summary of Contents for BMK-10i

Page 1: ...Operating Instructions Stud Welding Device BMK 10i GB English Version Read these operating instructions before starting any work Doc ID P00259 Date of issue 08 2017 www soyer com...

Page 2: ......

Page 3: ...d welding device BMK 10i Stud welding gun PH 9 SRM12 Stud welding gun PH 9 SRM12 G Stud welding gun PH 3N SRM Operating manual Document no P00259 08 2017 translation of the original German manual P001...

Page 4: ...l 17 3 Transport 19 4 Storage shutdown 19 5 Disposal 19 6 Description of the BMK 10i stud welding device 20 6 1 Type designation 20 6 2 Working method 20 6 2 1 Stud welding with SRM technology 21 6 2...

Page 5: ...ng device and the stud welding guns 52 11 2 1 Mains connection 52 11 2 2 Connecting the earth cable 52 11 2 3 Connecting the stud welding gun 53 11 2 4 Connecting the shielding gas supply 53 12 Settin...

Page 6: ...help you recognise any residual risks and prevent hazards The drawings and diagrams in this operating manual help illustrate the content and may vary slightly from the actual equipment The manufacture...

Page 7: ...centring tip MF threaded studs SOYER threaded studs with a reduced flange diameter MF stands for mini flange 1 4 Declarations of conformity The devices are built according to the generally accepted co...

Page 8: ...f the listed guidelines and standards Any unauthorised modification to this machine automatically annuls this declaration Designation of machine Stud welding device Machine type BMK 10i Machine no ___...

Page 9: ...cific use of the devices Information about the scope and costs of instruction and training can be obtained from Soyer GmbH 1 7 Standards and directives The following standards among others must be obs...

Page 10: ...mminently hazardous situation which will result in serious injury or death This safety alert indicates a potentially dangerous situation which could result in serious physical injury or death This saf...

Page 11: ...nger to life from Work on electrical or electronic modules may only be carried out by electrotechnically qualified personnel and carried out in line with the currently applicable electrotechnical regu...

Page 12: ...must be disconnected If protection devices have to be removed for maintenance work the device must only be switched on again when all protection devices are mounted again and their functionality has b...

Page 13: ...work on hot parts of the device check that they have cooled down Do not hold the gun tight in the welding area Danger of burns from hot welding spatter Dangerous welding spatter can occur during the...

Page 14: ...from its position with the gun cables Make sure especially with mobile use of your own good stability during welding Do not hold the workpiece in your hands during welding The workpiece must be secure...

Page 15: ...d the instructions concerning protective equipment in the following overview Recommended personal protection equipment Protective goggles During welding welding spatter and a flash occur Wear suitable...

Page 16: ...1 Incorrect use Any use other than the intended use of the device is deemed to be non intended Any use other than intended use unauthorised modification or manipulation of the device will void the dec...

Page 17: ...nformity with intended use The operating manual must be stored in the vicinity of the device The device operating company must ensure that the device is only used when all protective equipment is pres...

Page 18: ...plies Work on current carrying elements may only be performed by qualified electricians The work must be carried out in line with the applicable technical rules for electrotechnical devices All device...

Page 19: ...4 Storage shutdown Protect the device against dirt and humidity during storage or shutdown Protect the device against unauthorised access by third parties 5 Disposal Local environmental guidelines for...

Page 20: ...SRM technology was specially developed for mobile use Thanks to SRM the BMK 10i mobile welding device enables problem free welding even in constrained positions The BMK 10i works on the basis of a com...

Page 21: ...e sheet thickness to the stud diameter previously 1 4 where the use of ceramic rings can be dispensed with The versatile advantages of the SRM process provides completely new application options in th...

Page 22: ...cking at the same time Moreover it ensures a concave fillet weld bead formation with a blank metallic surface which reduces the risk of corrosion and achieves better dynamic characteristics of the wel...

Page 23: ...front Item Designation a Selection and display area with display and function keys see chapter 6 3 1 Display and setting area on page 25 b Shielding gas connection of the gun coupling socket KD 1 4 c...

Page 24: ...lzenschwei technik Figure 2 Overview of the back of the device Item Designation a Type plate b Fuse element with fuse 1 AT c Gas connection d Carrying belt e Mains switch for switching the device on o...

Page 25: ...2 1 5 Setting the lift time height of lift in the Setup mode on page 62 The LED next to the selected function lights up b keys For setting the value of the selected function shown on the display c Dis...

Page 26: ...Current source Inverter technology Welding current 100 600 A stud welding Welding time 20 up to 500 ms Welding sequence 3 mm up to 12 studs min 8 mm up to 3 studs min Mains connection 3 x 400 volt 10...

Page 27: ...lowing The use of other guns or guns from another manufacturer will invalidate the declarations of conformity and the warranties of SOYER Overview of permitted stud welding guns Gun Comments PH 9 SRM1...

Page 28: ...e carried out by qualified electricians in accordance with the electrotechnical codes of practice Cleaning agents must not get into the device Do not use aggressive cleaning agents for cleaning the de...

Page 29: ...5217 SRM stud chuck M12 F05219 The stud chuck in the gun must be installed changed in accordance with the stud diameter Adjustable stud chucks must be set to the stud length 7 1 Setting the SRM stud c...

Page 30: ...tep 2 Insert the stud into the stud chuck Step 3 Set the end stop screw so that the top edge of the stud flange when it is sitting on the screw sits between 3 mm and 5 mm above the stud chuck Step 4 F...

Page 31: ...time f Gas insert for shielding gas cap S12 g SRM supply for connection with the stud welding device h Gas supply for connection with the stud welding device i Support tube insert SRM12 The gun has a...

Page 32: ...ed in the technical data 8 1 Technical data of the PH 9 SRM12 stud welding gun Designation PH 9 SRM12 stud welding gun Item no P02276 Welding process Drawn arc stud welding DA SRM welding process Stud...

Page 33: ...ee chapter 7 1 Setting the SRM on page 29 Step 3 Undo the union nut Step 4 If there is still a stud chuck in the gun remove it Using pliers as an aid makes removal easier Step 5 Remove the tripod with...

Page 34: ...the gun Step 9 Hand tighten the union nut Step 10 Insert a stud and check the stud protrusion The stud stud flange must protrude 1 1 5 mm out of the shielding gas cap If necessary correct the setting...

Page 35: ...e SRM12 support tube insert Step 1 Switch off the stud welding device if the gun is connected to the stud welding device Step 2 Undo the two threaded pins on the tripod housing Step 3 Remove the old s...

Page 36: ...a suitable tool The frequency of cleaning depends on conditions under which the stud welding gun is used Danger of injury when cleaning Welding spatter and slag can have sharp edges Wear protective gl...

Page 37: ...c Trigger button d Power and control cables for connection with the stud welding device e Adjustment wheel for setting the height of lift lift time f Gas insert for SRM12 G shielding gas cap between...

Page 38: ...etermined using the lift time with the aid of the stud welding device To do so observe chapter 12 1 5 Setting the lift time height of lift in the Setup mode on page 62 The height of lift is set using...

Page 39: ...i BMK 16i when using the adapter Control cable adapter F06770 FA Earth cable adapter F06771 FA Gas adapter F06772 FA Weight 1 3 kg without cable Subject to technical changes 9 2 Operation of the PH 9...

Page 40: ...ess only the trigger button b on the gun The Start LED on the device display must not light up Now press all three trigger buttons a and b The Start LED on the device display must now light up 9 2 2 W...

Page 41: ...ud see chapter 7 1 Setting the SRM on page 29 Step 3 Undo the union nut Step 4 If there is still a stud chuck in the gun remove it Using pliers as an aid makes removal easier Step 5 Remove the tripod...

Page 42: ...the gun Step 9 Hand tighten the union nut Step 10 Insert a stud and check the stud protrusion The stud stud flange must protrude 1 1 5 mm out of the shielding gas cap If necessary correct the setting...

Page 43: ...eavy wear or impurity Item number for support tube insert F06748 Use original spare parts only Replacing the SRM12 support tube insert Step 1 Switch off the stud welding device if the gun is connected...

Page 44: ...to right and orientation are correct Step 6 Slide the new support ring up to the end stop in the mounting When installing make sure that the support tube insert and the mounting surface are clean Ste...

Page 45: ...ng a suitable tool The frequency of cleaning depends on conditions under which the stud welding gun is used Danger of injury when cleaning Welding spatter and slag can have sharp edges Wear protective...

Page 46: ...ght of lift lift time f SRM supply for connection with the stud welding device g Gas supply for connection with the stud welding device The gun has a lift magnet Before welding the stud is lifted by a...

Page 47: ...ss Drawn arc stud welding SRM welding process Stud diameter M3 M12 depending on the stud welding device Stud chuck SRM stud chuck and SRM nut holder Stud length Standard to 60 mm special lengths possi...

Page 48: ...required stud see chapter 7 1 Setting the Setting the SRM on page 29 Step 3 Remove the tripod with the shielding gas cap To do so undo the four socket head screws It is not essential to remove the tri...

Page 49: ...nsert a stud and check the stud protrusion The stud stud flange must protrude 1 1 5 mm out of the shielding gas cap If necessary correct the setting of the stud chuck by shifting the tripod Step 9 Fas...

Page 50: ...a suitable tool The frequency of cleaning depends on conditions under which the stud welding gun is used Danger of injury when cleaning Welding spatter and slag can have sharp edges Wear protective g...

Page 51: ...ith the legal requirements Ensure that the installation location has good accessibility all round for maintenance work Make sure that the stud welding device is not soiled by work causing dust especia...

Page 52: ...evice on page 26 When switching on the device all LEDs on the front panel light up briefly 11 2 2 Connecting the earth cable A secure earth connection must be established between the workpiece to whic...

Page 53: ...socket b and tighten the union nut Check whether the connection of the gun requires any special adapters see chapter 6 5 Permitted stud welding guns on page 27 11 2 4 Connecting the shielding gas sup...

Page 54: ...t off valve c Pressure gauge for indicating the gas pressure in the gas cylinder bar d Gas flow rate meter l min pressure reducing valve e Shut off valve for the gas connection hose of the stud weldin...

Page 55: ...Step 2 Connect the gas connection hose to the pressure reducing valve of the gas cylinder and the stud welding device Step 3 Open the main valve of the gas cylinder and the shut off valve of the gas c...

Page 56: ...ylinder fittings and lines are always in a good condition Make sure there is an adequate supply of fresh air when using storing or transporting the gas cylinder Comply with the instructions of the gas...

Page 57: ...g current Welding time SRM current Gas preflow time and Lift time Height of lift is explained in the following To achieve an optimum stud welding result it is necessary to carry out some test welds wi...

Page 58: ...MF A2 50 250 190 0 3 M8 HZ 1 Steel 5 8 270 350 0 3 M8 HZ 1 A2 50 270 300 0 4 M8 HZ 1 Steel 8 8 270 400 0 4 M10 HZ 1 Steel 5 8 600 220 0 3 M10 HZ 1 A2 50 A5 50 600 200 0 5 M10 HZ 1 Steel 8 8 600 350 0...

Page 59: ...Connection of the stud welding device and the stud welding guns on page 52 Step 2 Use the arrow keys to select the position for the welding current setting The LED lights up if the selection is correc...

Page 60: ...setting is 0 A SRM is deactivated Setting deactivating the SRM current Step 1 Connect the device as described in chapter 11 2 Connection of the stud welding device and the stud welding guns on page 5...

Page 61: ...ssed shielding gas flows out of the shielding gas cap of the gun for the time set in seconds This means the gas lines can also be purged with shielding gas before starting work Setting the preflow tim...

Page 62: ...ot activated Operating modes Setup mode No welding is carried out when simulating a welding process Operating mode normal mode Welding is carried out Danger from incorrect operating mode If the follow...

Page 63: ...bles for device setting on page 58 Changing the lift time The lift time is changed using the adjustment ring on the welding gun for the height of lift of the stud Pull out the adjustment ring and turn...

Page 64: ...ints below when using and changing the setting for the PH 9 SRM12 G welding gun welding gun with integrated earth connection The lift can only be tested when the gun is positioned flush on the workpie...

Page 65: ...age 10 If you have any problems understanding the operating manual please contact the manufacturer Soyer Before each use check that the devices and the lines with the plugs are intact Carrying out wel...

Page 66: ...when the contact to the workpiece and earth connection are correct Step 8 Press the gun trigger button Welding is carried out The LEDs also briefly light up red during welding During the welding proc...

Page 67: ...2 1 Visual inspection Visual inspection is used for a rough check for major defects The uniformity of the weld is assessed here The following table serves as an aid for assessing a weld result Visual...

Page 68: ...the device Switch off the stud welding device at the mains switch This also automatically switches off the connected welding gun Make sure that the stud welding device cannot be switched on and used b...

Page 69: ...cables or gas hose correctly or examine for damage replace if necessary Connection plugs or sockets of the device are damaged Have the plugs or sockets replaced by SOYER customer service Both earth ca...

Page 70: ...regulating ball valve Solenoid valve in the device is soiled or defective Contact customer service and have it replaced Stud does not lift there is no main current arc although Stud on workpiece LED l...

Page 71: ...ght of lift and or the immersion depth in accordance with the operating manual for your welding gun You have used low quality studs with imprecise dimensions or poor surface quality Only use SOYER wel...

Page 72: ...ance between the stud chuck and the front surface of the stud Welding gun applied at a slant Press the gun onto the workpiece at an angle of 90 Lift not correctly set Adjust the lift The device switch...

Page 73: ...ontact your respective SOYER representative The contact data is available on our web site at www soyer de or www soyer com English 16 Warranty conditions The warranty period for commercial use or corr...

Page 74: ...Heinz Soyer Bolzenschwei technik GmbH Inninger Stra e 14 82237 W rthsee Tel 0049 8153 885 0 Mail info soyer de www soyer com www srm technology com...

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