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Soyer SRM EcoWeld BMK-20i Operating Instructions Manual Download Page 49

 

 

 

 

 

Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik 

49 

 
 

How to retrofit the PH-2L and PH-4L stud welding guns to drawn arc welding with inert 
gas 

Step 6: 

1.  Insert a weld stud. 
2.  Insert the support and check the stud 

protrusion. 

 
The  stud  /  stud  flange  must  protrude 
approx. 3 mm from the inert gas shroud. 
 
If  necessary,  correct  the  setting  of  the 
stud chuck by shifting the support. 
 

 

Step 7: 

Fasten the support by means of the Allen 
screws of the gun. 
 

 

The adjustment is complete. 

 
 
 

 

Summary of Contents for SRM EcoWeld BMK-20i

Page 1: ...Operating Instructions Stud Welding Device BMK 20i GB English Version Read these operating instructions before starting any work Doc ID P00265 Date of issue 06 2021 www soyer com...

Page 2: ......

Page 3: ...umber Stud welding device BMK 20i Stud welding gun PH 3N SRM Stud welding gun PH 2L Stud welding gun PH 4L Operating Instructions Document no P00265 06 2021 translation of the original German manual G...

Page 4: ...5 Disposal 18 6 Description of the BMK 20i stud welding device 19 6 1 Type designation 19 6 2 Working method 19 Stud welding with SRM Technology 20 Drawn arc stud welding technology using inert gas 21...

Page 5: ...ning the welding gun 54 10 Setup and connection 55 10 1 Requirements for the installation site 55 10 2 Connection of the stud welding device and the stud welding guns 56 Mains connection 56 Connecting...

Page 6: ...ch are intended to help you recognise any possible residual risks and prevent hazards The drawings and diagrams in these operating instructions are for illustration purposes and may vary slightly from...

Page 7: ...stands for mini flange PT threaded stud Capacitor discharge welding studs with thread IT tapped studs Capacitor discharge tapped studs RD threaded studs Drawn arc welding studs with thread 1 4 Declar...

Page 8: ...ts of the listed guidelines and standards Any unauthorised modification to this machine automatically annuls this declaration Designation of machine Stud welding device Machine type BMK 20i Machine no...

Page 9: ...r specific use of the devices Information on the scope and costs of instruction and training can be obtained from Soyer GmbH 1 7 Standards and directives The following standards inter alia must be obs...

Page 10: ...of the situation Safety and information symbols used in this manual Imminent danger leading to severe injuries or death Potentially dangerous situation that may lead to severe injuries or death Poten...

Page 11: ...ger to life from electric current Work on electric or electronic components may only be performed by trained electrotechnical personnel in accordance with currently applicable electrotechnical regulat...

Page 12: ...isconnected If protective devices have to be removed for maintenance work the device must only be switched on again when all protective devices are installed and their functionality has been checked D...

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

Page 14: ...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 securely fi...

Page 15: ...erve the following instructions for protective equipment Recommended personal protection equipment Protective goggles During welding welding spatters and a flash of light occur Wear appropriate safety...

Page 16: ...ert gas Drawn arc stud welding with ceramic ferrules Incorrect use Any use of the device deviating from the intended use is considered improper use Improper use unauthorised modification or manipulati...

Page 17: ...ud welding device The operator of the device must ensure that all protective devices are present active and intact before the stud welding device is used Please observe the DIN EN IEC 60974 9 standard...

Page 18: ...on the top The handle and carrying strap are intended exclusively for transport by hand Never pull ropes through the handle or carrying strap to lift the stud welding device by means of a crane to the...

Page 19: ...must be approved by SOYER The BMK 20i stud welding device operating with SRM Technology was specially developed for mobile use Thanks to SRM it enables problem free welding even under difficult condi...

Page 20: ...dvantages of the SRM procedure open up completely new possible applications in the entire stud welding sector Functional principle The stud tip touches the workpiece and is lifted The arc is initiated...

Page 21: ...with a metallically bright surface reducing the risk of corrosion and achieving a better dynamic behaviour of the welding joint When welding using inert gas without other aids it is not possible to p...

Page 22: ...cooling of the welding pool It partially protects against spraying sparks To ensure the formation of a welding bead each stud requires a ceramic ferrule matching its diameter and shape After each wel...

Page 23: ...m Designation a Selection and display area with display and function keys see chapter 6 3 1 Display and setting area on page 25 b Mains switch for turning the device ON OFF c Control cable connection...

Page 24: ...20i Heinz Soyer Bolzenschwei technik Figure 2 Overview of the back of the device Item Designation a Fuse element with fuse 1 AT b Mains supply cable c Gas connection KS 1 4 maximum permissible amount...

Page 25: ...s Lift test see chapter 11 1 5 Setting the lift height drop time in the Setup mode on page 67 The LED next to the selected function lights up keys For setting the value of the selected function shown...

Page 26: ...urrent source Inverter technology Welding current 100 1200 A stud welding Welding time 20 up to 500 ms Welding sequence 6 mm up to 12 studs min 16 mm up to 3 studs min Mains connection 3 x 400 V 10 15...

Page 27: ...and warranties of Soyer GmbH Overview of permitted stud welding guns Gun Note PH 3N SRM item no P02249 Standard gun with SRM Technology PH 2L 1 SRMXL inert gas or ceramic ferrule PH 4L 1 SRMXL inert g...

Page 28: ...y be carried out by skilled electricians in accordance with the electrotechnical regulations Make sure that no detergents get into the device Do not use aggressive detergents for cleaning the device M...

Page 29: ...4 Order number F05353 SRM stud chuck M16 Order number F05275 The stud chuck in the gun must be installed changed in accordance with the stud diameter Different stud diameters require different stud ch...

Page 30: ...huck according to the required stud diameter Step 3 Insert the stud into the stud chuck Step 4 Set the stop screw so that the stud when it is sitting on the screw is about 5 mm above the stud chuck If...

Page 31: ...gh there is a risk of scorching during the welding process Figure shows PH 2L PH 4L is similar Stud chucks for drawn arc operation HZ stud chuck M6 Order number F01190 HZ stud chuck M8 Order number F0...

Page 32: ...eight drop time f SRM supply for connection to the stud welding device g Gas supply for connection to the stud welding device The gun is equipped with a lifting magnet Before welding the stud is lifte...

Page 33: ...Drawn arc stud welding Stud diameter M3 M12 depending on the stud welding device preferably with SOYER HZ 1 weld studs Stud chuck SRM stud chuck and SRM nut holder Stud length Standard up to 60 mm sp...

Page 34: ...o the desired stud see chapter 7 1 1 Setting the SRM stud chuck on page 29 Step 3 Remove the support with the inert gas shroud To this end loosen the four Allen screws It is not essential to remove th...

Page 35: ...Step 8 Insert a stud and check the stud protrusion The stud stud flange must protrude 1 1 5 mm from the inert gas shroud If necessary correct the settings of the stud chuck by shifting the support St...

Page 36: ...on conditions under which the stud welding gun is used Danger of injury when cleaning Switch the stud welding device off when the gun is connected to the stud welding device Danger of injury when clea...

Page 37: ...l for setting the speed of immersion damping e Release button f Adjustment wheel for setting the lift height drop time g Power and control cable for connection to the stud welding device h SRM supply...

Page 38: ...lding gun Item no P02225 Welding process SRM welding process preferred Drawn arc stud welding Stud diameter M6 M16 M8 M12 preferred depending on accessory and stud welding device Stud chuck SRM stud c...

Page 39: ...ng the damping of the PH 2L stud welding gun Switch off the stud welding device when the gun is connected to it Adjusting the damping to ON 1 Loosen the lock screw a by turning it to the left 2 Manual...

Page 40: ...t height drop time g Power and control cable for connection to the stud welding device h SRM supply for connection to the stud welding device i Gas supply for connection to the stud welding device The...

Page 41: ...welding gun Item no P02250 Welding process SRM welding process preferred Drawn arc stud welding Stud diameter M6 M16 M10 M16 preferred depending on accessory and stud welding device Stud chuck SRM stu...

Page 42: ...oosen the lock screw a by manually turning it to the left until stop Infinite adjustment of the damping Manually turn the adjustment screw a to the right until the desired damping is reached The large...

Page 43: ...dapter for SRM stud chuck Item no F01375 and F01619 Inert gas supply SRMXL support with SOYER SRM Technology Depending on the scope of delivery your welding gun is already equipped with a SRMXL suppor...

Page 44: ...during the welding process When using the PH 2L or PH 4L stud welding gun the stop screw must be shortened to a maximum projection of 5 mm If the setting screw is too long the stud chuck cannot be fu...

Page 45: ...e stud chuck to the desired stud see chapter 7 1 1 Setting the SRM stud chuck on page 29 Step 3 If the gun is equipped with a support remove it if need be To this end loosen the two Allen screws It is...

Page 46: ...to a support with SRM Technology Step 8 Insert a stud and check the stud protrusion The stud stud flange must protrude 1 1 5 mm from the inert gas shroud If necessary correct the setting of the stud...

Page 47: ...See also chapter 6 2 2 Drawn arc stud welding technology using inert gas on page 21 For this you also need the following Support for inert gas Item no F04681 FA Drawn arc stud chuck see chapter 7 2 Dr...

Page 48: ...onnected to it Step 2 If the gun is equipped with a support remove it if need be To this end loosen the two Allen screws It is not essential to remove the support however this makes use easier Step 3...

Page 49: ...ing with inert gas Step 6 1 Insert a weld stud 2 Insert the support and check the stud protrusion The stud stud flange must protrude approx 3 mm from the inert gas shroud If necessary correct the sett...

Page 50: ...arc stud welding technology with ceramic ferrules on page 22 For this you also need Support for ceramic ferrule see chapter 15 1 Spare and conversion parts for drawn arc welding with ceramic ferrules...

Page 51: ...o chapter 15 1 Spare and conversion parts for drawn arc welding with ceramic ferrules on page 78 Step 2 Depending on the ceramic ferrule it may be necessary to readjust the ferrule grip The ceramic fe...

Page 52: ...pped with a support remove it if need be To this end loosen the two Allen screws It is not essential to remove the support however this makes use easier Step 3 It may be necessary to remove a screwed...

Page 53: ...rrule support Step 7 Fasten the ceramic ferrule support by means of the Allen screws of the gun Step 8 Check whether the stud is centrically aligned in the ceramic ferrule grip The stud must not tilt...

Page 54: ...ng depends on conditions under which the stud welding gun is used Danger of injury when cleaning Switch off the stud welding device when the gun is connected to it Danger of injury when cleaning Weldi...

Page 55: ...must comply with legal requirements Ensure that the installation site is readily accessible for maintenance work Make sure that the stud welding device cannot be soiled by dust especially metal dust o...

Page 56: ...4 Technical data of the BMK 20i stud welding device on page 26 When switching on the device all LEDs on the front panel light up briefly Connecting the earth cable A secure earth connection must be es...

Page 57: ...ble socket b and tighten the union nut Make sure to check if special adapters are required to connect the gun see chapter 6 5 Permitted welding guns on page 27 Connecting the inert gas supply Prior to...

Page 58: ...w b Main shut off valve c Manometer for displaying the gas pressure in the gas cylinder bar d Gas flow meter l min pressure reducing valve e Shut off valve for the gas connection hose of the stud weld...

Page 59: ...gas cylinder and the stud welding device reverse side Step 3 Open the main valve of the gas cylinder and the shut off valve of the gas connection hose Step 4 Use the regulating valve to set an inert...

Page 60: ...re the gas cylinder 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 instruction...

Page 61: ...ng parameters Welding current Welding time SRM current Gas preflow time and Drop time lift height are adjusted To achieve an optimum stud welding result it is necessary to carry out some test welds wi...

Page 62: ...8 550 110 0 30 M8 HZ 1 St 8 8 550 110 0 30 M8 HZ 1 A2 50 480 110 0 40 M10 HZ 1 St 5 8 800 100 0 25 M10 HZ 1 St 8 8 650 180 0 25 M10 HZ 1 A2 50 700 140 0 25 M12 HZ 1 St 5 8 800 180 0 25 M12 HZ 1 St 8...

Page 63: ...A2 50 230 180 0 60 M6 weld nut A2 50 270 250 0 70 M8 weld nut A2 50 370 350 0 75 M10 weld nut A2 50 500 450 1 15 M12 weld nut A2 50 600 500 1 25 RD M6 St 4 8 420 90 0 30 RD M6 A2 50 360 100 0 40 RD M...

Page 64: ...pter 10 2 Connection of the stud welding device and the stud welding guns on page 56 Step 2 Use the arrow keys to select the position for the welding current setting The LED lights up if the selection...

Page 65: ...o 0 A SRM is deactivated You can deactivate the SRM current for the following welding procedures Drawn arc stud welding with inert gas Drawn arc stud welding with ceramic ferrule Setting deactivating...

Page 66: ...the inert gas shroud of the gun As soon as the release button on the gun is pressed inert gas flows out of the inert gas shroud of the gun for the time set in seconds This means the gas lines can als...

Page 67: ...ent is not 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 th...

Page 68: ...rrect drop time can be found in chapter 11 1 1 Support tables for device settings on page 62 The lift height drop time is changed using the adjustment ring on the welding gun for the lift height of th...

Page 69: ...t the manufacturer Soyer Before each use check that the devices and the cables lines with the plugs are undamaged Carrying out welding When working with the stud welding device we recommend wearing pe...

Page 70: ...e of the upper three functions Step 8 Check that the welding points on the stud and workpiece are metallically bright Step 9 Press the gun onto the workpiece at an angle of 90 degrees The LEDs light u...

Page 71: ...ual inspection The visual inspection serves as a rough check for major defects The uniformity of the weld is assessed The following table serves as an aid for the assessment of the welding result Visu...

Page 72: ...the connected welding gun Make sure that the stud welding device cannot be switched on and used by unauthorized persons Close the shut off valves at the gas supply If the stud welding device is not us...

Page 73: ...ct the 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 e...

Page 74: ...with the 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 workp...

Page 75: ...the lift height 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...

Page 76: ...to 3 5 mm distance between the stud chuck and the front surface of the stud The welding gun was placed in tilted position Press the gun onto the workpiece at an angle of 90 Lift not correctly set Adju...

Page 77: ...k GmbH or authorised specialists 14 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 Ema...

Page 78: ...or welding with ceramic ferrules Individual parts in the conversion kit Item Designation Dimension Item no a Support rod n Length 230 mm F02879 b Foot plate FP1 KR 6 KR 10 F01642 c Foot plate FP2 KR 1...

Page 79: ...terschlag 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 accessorie...

Page 80: ...Heinz Soyer Bolzenschwei technik GmbH Inninger Stra e 14 82237 W rthsee Tel 0049 8153 885 0 Mail info soyer de www soyer de...

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