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BMK-8 U / BMK-12 W

Operating Instructions

BMK-8 U
BMK-12 W
Stud Welders

Serial number*

Stud welder BMK- _________________________

Please enter your type of stud welder and serial number here, so that these

data are immediately available if you need service support

Survey of stud welder types

Order no. Code designation

Note

P01315

BMK-8 U

Standard device 3 x 230 up to 500 V power supply

P01331

BMK-12 W

Standard device (3 x 400 V power supply)

P01332

BMK-12 W automatic

Standard device (3 x 400 V power supply)
and automatic set for stud reload

P01333

BMK-12 W universal

Special device (3 x 230 up to 500 V power supply)

P01334

BMK-12 W universal
automatic

Special device (3 x 230 up to 500 V power supply)
and automatic set for stud reload

P01337

BMK-12 W / C

Special device (3 x 400, 460, 600 V power supply)

Heinz Soyer Bolzenschweißtechnik GmbH
Etterschlag
Inninger Straße 14
82237 Wörthsee
Tel49 (0) 8153 - 885 - 0
T49 (0) 8153

– 8030

www.soyer.de

Содержание BMK-12 W

Страница 1: ...Operating Instructions BMK 8 U BMK 12 W Stud Welders...

Страница 2: ...BMK 8 U BMK 12 W 2...

Страница 3: ...V power supply P01331 BMK 12 W Standard device 3 x 400 V power supply P01332 BMK 12 W automatic Standard device 3 x 400 V power supply and automatic set for stud reload P01333 BMK 12 W universal Speci...

Страница 4: ...ed trade mark of Heinz Soyer Bolzenschwei technik GmbH It is prohibited to transmit or reprint this document as well as to utilize or disclose its contents unless this has been expressly granted Non c...

Страница 5: ...modification to this machine automatically annuls this declaration Designation of machine Stud welding device Machine type BMK 12W BMK 12W automatic BMK 12W universal BMK 12W universal automatic Machi...

Страница 6: ...lding gas 15 3 2 2 Short cycle drawn arc welding with ceramic ferrules 15 3 3 Construction of the BMK 8U BMK 12W stud welders 15 3 4 Technical data 16 3 5 BMK 12 W interfaces 17 3 5 1 CNC interface 17...

Страница 7: ...elding operation with ceramic ferrules 39 6 5 1 Instructions for welding with ceramic ferrules 39 7 Quality control 41 7 1 General 41 7 2 Demands on the company 41 7 3 Test execution 41 7 3 1 Producti...

Страница 8: ...operated near electronically sensitive life supporting equipment such as in intensive care units in hospitals Persons with pacemakers must neither operate the stud welding equipment nor stay near it...

Страница 9: ...h as oil fuel etc must be removed prior to the start of work Electronic equipment e g airbags and the use of explosive substances for fuel supply require further safety precautions when carrying out w...

Страница 10: ...may cause damage to the product or to an object surrounding it Instructions for application and other useful information facilitating the proper use of the product Safety symbols The following pictog...

Страница 11: ...nsequences Failure of important system functions Failure of prescribed methods for maintenance Danger of persons through electric mechanic thermal and acoustic influences 1 4 Before starting to weld C...

Страница 12: ...lication The BMK 8 U BMK 12 W SOYER stud welders for short cycle drawn arc welding allow SOYER threaded studs made of plain steel stainless steel and heat resistant steel as per DIN EN ISO 13918 to be...

Страница 13: ...he implementation of these operating instructions CAUTION Do not carry out any actions on the stud welding equipment without specifically knowing the operating instructions or the respective part Ensu...

Страница 14: ...also possible to weld nickel and titanium depending on the respective requirements Standard studs for drawn arc and capacitor discharge welding in compliance with DIN EN ISO 13918 can be welded witho...

Страница 15: ...ve fillet weld upset formation with a blank metallic surface thus reducing the risk of corrosion and obtaining an improved dynamic behaviour of the welded joint An accurate bulging to scale or in a ca...

Страница 16: ...2 A 3P protective earth conductor 3 x 400 V 50 60 Hz standard 3 x 230 3 x 440 3 x 460 3 x 500 or 3 x 600 V 50 60 Hz possible depending on the special type OPTION E constant current 0 3 A phase E const...

Страница 17: ...external Terminology SOW Stud on workpiece Shows contact between stud and workpiece Contact is necessary to start welding process via the starting signal Start Contact releases the welding process EP...

Страница 18: ...process This state represented as Transformer overheated please wait is shown alternately with the current operation mode on the display Only when this information is no longer shown on the display is...

Страница 19: ...tion for welding guns or heads with automatic stud feed 9 Control cable connection 10 Welding cable socket The control cable connection and the welding cable socket serve to connect the stud welding g...

Страница 20: ...9 pin connector interface RS 232 OPTION This interface serves to be connected with an external control system 17 Danger sign 18 Type plate 19 Shielding gas connector This connection serves to supply...

Страница 21: ...Function key arrow left 6 4 Function key arrow right R Function keys arrow up down Modification of selected parameters flashing symbol in display Function keys arrow left right Selection of parameter...

Страница 22: ...set It is possible to set four different operation modes 1 OP Operating state which must be set for normal welding operation 2 PRE Preweld current test 3 LIFT Lift test 4 GAS Gas test MCT Main curren...

Страница 23: ...al interface RS232 not yet in use Function key ALTER PARAMETERS Upward alteration of the selected parameters represented blinking in the display Function key ALTER PARAMETERS Downward alteration of th...

Страница 24: ...e of the connecting route of both earth clamps This guarantees a current distribution around the stud that is balanced to the largest possible extent and satisfactory welding results Difficult areas a...

Страница 25: ...n with sleeve nut Please also refer to the information given in the operating instructions for the welding guns 5 1 8 Mains supply Compare the power data supply voltage current consumption on the type...

Страница 26: ...which may be set are also listed in chapter 5 1 3 5 2 2 1 Operating mode OP operating state The operating mode OP allows normal welding operation with the welding parameters set In the case of an exc...

Страница 27: ...selected pre current and main current period 5 2 2 3 Operation mode LIFT lift test This operation mode enables you to adjust and check the lift of the gun or welding head For further information pleas...

Страница 28: ...If the workpiece is not connected to the earth connection no ground appears on the display Do not activate the release too often in short intervals as this would cause the thermo safety mechanism pro...

Страница 29: ...ial functions 5 3 1 Special function Erasing the working storage This special function serves as RESET function e g for eliminating troubles or starting the stud welder the first time All settings of...

Страница 30: ...r connected can be set by means of parameter 5 To call this special function please proceed as follows Simultaneously press arrow right and arrow left keys and keep them pressed Switch stud welder on...

Страница 31: ...conjunction with a BMK feeder This parameter serves to adjust the post vibration period of the feeder to fill the outlet rail when a stud has been brought in blow off position The after vibration peri...

Страница 32: ...n setting feeder type BMS or Display when setting feeder type BMK By using the function keys arrow left or arrow right you can move the slider in the feeder s stud escapement to the left or right end...

Страница 33: ...tend the main current at the end of the welding process Depending on the respective welding task this special function allows the weld quality to be improved CAUTION Please observe that the extension...

Страница 34: ...so please refer to the standard values indicated in the list Welding parameters 6 1 1 1 MCTIME main current time Select function MCTIME by pressing either function key arrow left 3 or arrow right 4 Se...

Страница 35: ...d time The reload time is the period of time the blast air valve requires for transporting the stud from the universal feeder to the welding gun or welding head The longer the blast air hose is the hi...

Страница 36: ...0 190 40 40 300 300 RD 10 250 40 40 400 400 Table for BMK 12W ms ms ms M3 5 40 0 M4 RD 6 10 30 40 40 0 300 M5 PD 6 15 50 40 40 0 300 M6 RD 8 30 80 40 40 300 300 M8 PD 8 80 100 40 40 300 300 M10 RD 10...

Страница 37: ...The welding process will be started with the parameters set The LED Final contact indicates the end of the welding process Do not move the welding gun or welding head during welding Wait until the we...

Страница 38: ...Flow meter Screwing out decreases the flow Connect gas supply hose and gas hose of pressure reducing valve to the stud welder Pressure reducing valve is not included in delivery Open hand wheel item 2...

Страница 39: ...ceramic ferrules The measures mentioned in the Start up of stud welder chapter have already been performed 1 Foot plate 2 Ceramic ferrule 3 Welding stud Illustration Stud welding with ceramic ferrule...

Страница 40: ...ocess The LED Final contact lights up after completion After completion of the welding process the welding gun or welding head should be held in position for about 5 seconds to allow solidification of...

Страница 41: ...lding DVS 0904 Practical information Arc stud welding 7 2 Demands on the company The company must employ a technical supervisor responsible for welding matters as well as qualified operating personnel...

Страница 42: ...oor weld quality e g caused by excessive welding energy or insufficient plunge or lift Reduced diameter weld Partial weld Poor weld quality e g caused by insufficient welding energy or humid ceramic f...

Страница 43: ...iate tension device until they break If the customer demands that a certain percentage of the welded studs should be tested with a specific test load in production a tension device with load indicator...

Страница 44: ...and appropriately qualified personnel are allowed to carry out works at the electric mains supply and welding system NOTE Only use original SOYER spare parts 8 3 Cleaning Cleaning should be carried o...

Страница 45: ...lp you eliminate any trouble immediately on the spot If it is difficult or impossible to eliminate the trouble please contact the SOYER customer service responsible for your area or Heinz Soyer Bolzen...

Страница 46: ...k for damage Replace if necessary Connecting plug or socket of stud welder is burnt down Have plug or socket replaced by SOYER customer service Both earth cables are not properly connected or not conn...

Страница 47: ...d earth clamps for tight fit Stud too loose or not fully inserted into stud holder until stop Insert stud into stud holder until stop Replace stud holder if necessary Magnetic blowing action Arc is fo...

Страница 48: ...on again Insufficient mains supply i e supply voltage below value required for welding operation Connect stud welder without extension cable to mains supply If you need to use an extension cable use o...

Страница 49: ...OTE Prevent unauthorized use of the stud welding systems by children and unqualified personnel After long system standstill we recommend having the stud welding system checked by SOYER customer servic...

Страница 50: ...902 Drawn arc stud welding DVS Information Sheet 0903 Capacitor discharge stud welding with tip ignition DVS Information Sheet 0904 Practical information Arc stud welding EN 14555 Arc welding of metal...

Страница 51: ...BMK 8 U BMK 12 W 51 Notes...

Страница 52: ...immersion 5 1 5 Adjusting the height of lift 6 2 Start up 7 2 1 Total view 7 2 2 Connecting stud welding gun to stud welder 7 2 3 Operation 7 2 4 Welding parameters 8 3 Spare parts Wear parts 9 3 1 A...

Страница 53: ...stud holder with adjusting screw having a length of 73 mm Ensure that the maximum stud length does not exceed 60 mm 1 Stud 3 Lock nut 2 Stud holder 4 Stop screw Different stud holders are required for...

Страница 54: ...holder must be screwed on the adapter piece tightly When the screwed connection is not tight enough these parts could be damaged by scorching during the welding process Drawn arc stud holders are esp...

Страница 55: ...ding gun with support tube The standard PH 3 stud welding gun uses a gas shroud instead of a support tube 6 The description of installation refers to PH 3 PH 3N and PK 3 stud welding guns 1 Stud holde...

Страница 56: ...rt tube When placing the welding gun on the workpiece the stud is pushed back this distance During welding the stud will immerse up to this length into the liquid weld pool on the workpiece The proces...

Страница 57: ...stud 3 are lifted from workpiece 1 The lift is adjusted with the help of the adjusting screw 6 located at the back of the welding gun How to adjust the height of lift Insert screwdriver into the groov...

Страница 58: ...lding cable into the relevant jack at the stud welder Insert connector of stud welding gun s control cable into the relevant jack at the stud welder Insert gas supply connector of stud welding gun int...

Страница 59: ...he operating instructions of your stud welder Before starting your work carry out some experimental welds and test them to find out the optimum adjustment Samples have to be taken during production to...

Страница 60: ...hutzgasglocke SGL 2 Aluminium SGL 2 gas shroud aluminium 0 06 F01631 1 Schutzgasglocke Aluminium Gas shroud aluminium SGL 1 0 063 F02477 1 Schutzgasglocke Messing Gas shroud brass SGL 2 0 183 F02476 1...

Страница 61: ...erst ck M10 Adapter piece M10 0 025 F02000 FA 2 Massekabel mit Gripzange komplett f r BMK 10 12 Earth cable with locking pliers complete for BMK 10 12 1 426 F01666 FA 2 Massekabel mit Zwinge f r BMK B...

Страница 62: ...Keramikringhalter Ceramic ferrule holder 0 013 F03769 KR8 10 Keramikringhalter Ceramic ferrule holder 0 013 F03770 KR12 Keramikringhalter Ceramic ferrule holder 0 018 F02115 1 Stativgrundplatte f r K...

Страница 63: ...2 200 mm 0 07 F03166 2 250 mm 0 088 F03781 2 300 mm 0 106 F03782 2 400 mm 0 143 F03717 FA 1 Verl ngerung Pistolenkabel 3 m Extension gun cable 3 m 2 180 F03748 FA 1 Verl ngerung Pistolenkabel 5 m Exte...

Страница 64: ...clip white E02858 17 1 Grub screw 8x8 DIN916 18 1 Strain relief F03012 19 1 Bend protection E02854 20 3 m Fabric tube M01390 21 4 Cable fastener 100 25 E02072 22 0 35 m Silicone tube 8x2 0 M01396 23 1...

Страница 65: ...head screw M3x20 DIN912 47 1 Acorn nut M4 DIN6797A 48 1 Tooth lock washer M4 DIN6797A 49 1 Fillister head screw M4x8 DIN ISO 7380 50 3 Spring thrust piece M4x10 51 1 Gun label for PH 3N M03596 52 1 S...

Страница 66: ...Appendix A REV1 Adjustment of short cycle drawn arc welding guns Appendix A 15 3 5 Illustration of PH 3N stud welding gun main view PH 3N 26 225 002...

Страница 67: ...Appendix A Adjustment of short cycle drawn arc welding guns Appendix A 16 3 6 Illustration of PH 3N stud welding gun section of gun body 225 002...

Страница 68: ...Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger Stra e 14 D 82237 W rthsee Tel 49 0 81 53 8 85 0 Fax 49 0 81 53 80 30 Internet www soyer de E Mail info soyer de...

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