Operating Instructions Stud Welding Device BMK-10i
GB
: English
V
ersion
Read these operating instructions before starting any work!
Doc.ID:
P00259
Date of issue: 08.2017
www.soyer.com
Страница 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...
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Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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 ___...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
