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Summary of Contents for Soyer BMK-8i ACCU
- Page 1 Operating Instructions Stud welding device BMK-8i ACCU SRM® technology Stud welding gun PH-9 SRM PH-9 SRM PH-3N SRM...
- Page 2 Stud welding gun PH-9 SRM PH-9 SRM PH-3N SRM Operating Instructions Document no.: P00163, 09-2019, Original instructions (English: P00263) All information in this document is the property of Heinz Soyer Bolzenschweißtechnik GmbH. Revision status Document created/amended Editor Date Original Created...
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Page 3: Table Of Contents
6. Disposal ............23 7. Description of the BMK-8i ACCU stud welding device....24 7.1. - Page 4 CONTENTS 7.3.2 Battery charging and status indicators 7.4. Technical data of the BMK-8i ACCU stud welding device 7.4.1 Maximum settings 7.5. Permitted stud welding guns 7.6. Cleaning the stud welding device 8. Description of the SRM® stud chuck ....... . 36 8.1.
- Page 5 17. Warranty conditions ..........80 Operating Instructions Soyer Bolzenschweißtechnik...
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Page 6: General Information
The following terms in these instructions are used with registered trademarks: SRM®: SRM corresponds to magnetic field stud welding and stands for stud welding in a radially symmetric magnetic field [in German: Schweißen im radialsymmetrischen Magnetfeld]. SOYER®: Developments/technologies of Soyer GmbH. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 7: Abbreviations And Definitions
HZ-1 threaded stud: SOYER® universal stud with centring tip. MF threaded stud: SOYER® threaded stud with a reduced flange diameter (“MF” stands for “mini flange”). 1.4 Declarations of conformity The devices are designed and constructed in accordance with the general accepted codes of practice. - Page 8 General information Stud welding device Heinz Soyer Bolzenschweißtechnik GmbH Heinz Soyer Bolzenschweißtechnik GmbH Heinz Soyer Bolzenschweißtechnik GmbH Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 Inninger Straße 14 Inninger Straße 14 Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 82237 Wörthsee 82237 Wörthsee 82237 Wörthsee...
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Page 9: Manufacturer
Web: www.soyer.de, www.soyer.com 1.6 Instruction, training Soyer offers optional and individual instruction in the operation of the devices. Moreover, Soyer offers training for customer-specific use of the devices. Information on the scope and costs of instruction and training can be obtained from Soyer GmbH. -
Page 10: Important Safety Instructions
Do not touch or open, danger to unauthorised per- sons. Danger to persons with medical implants such as pacemakers. The information sign is not a warning sign. It indi- cates important and useful information on the sub- ject. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 11: General Safety Instructions
• Starting the device with faulty protection devices is not permitted. Faulty protective devices must be repaired or replaced immediately. Unintentional operation by third parties must be prevented. Operating Instructions Soyer Bolzenschweißtechnik... - Page 12 • Work on electric or electronic components may only be performed by trained electrotechnical personnel of Soyer Bolzenschweißtechnik. • Before performing any work on the stud welding device, the mains switch of the device must be turned off and the mains plug must be disconnected.
- Page 13 WARNING Danger of fire from hot welding spatters Welding spatters or hot workpieces occurring during the welding process may cause danger of fire. • Do not store combustible or highly flammable materials in the welding area. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 14: Safety Instructions Regarding The Working Method
Do not look directly into the flash of light. • The gun carries out lifting movements during the welding process. Do not hold the gun in the area of moving parts. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 15: Electromagnetic Fields - Implants
These include, for example, access restrictions for passers-by or individual risk assessments for welders. Risk assessments and recommendations for people with medical devices and implants must be carried out by a doctor. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 16: Personal Protective Equipment
Welding spatters occur during the welding process. Wear appropriate, incombustible, heat-resistant safety footwear. Hearing protection Relatively loud welding noises may occur, depending on the welding device and the welding application. In that case, wear appropriate hearing protection. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 17: Intended Use Of The Stud Welding Device
Special studs or diameters upon request. The stud welding device can only be operated with the welding guns described in chapter “7.4 Technical data of the BMK-8i ACCU stud welding device” on page 31. The stud welding device must be operated within the scope of technical data. -
Page 18: Incorrect Use
If welding personnel has to be qualified for certification of welding, the standards DIN EN ISO 14555 and DIN EN ISO 14732 are to be observed. Operating Instructions Soyer Bolzenschweißtechnik... - Page 19 Works on live elements may only be performed by authorised electricians. This personnel work must be performed in accordance with the applicable technical rules for electrotechnical devices. All devices of Soyer Bolzenschweißtechnik GmbH must only be opened by personnel of Soyer or personnel authorised by Soyer. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 20: Important Safety Instructions For Battery Operation
Do not charge batteries for an extended period if they are not used. • Do not charge batteries at temperatures below 0 °C. • The batteries may only be used in the SOYER® devices for which they are intended. Operating Instructions Soyer Bolzenschweißtechnik... - Page 21 • Never dispose of batteries in household waste. • Do not dispatch batteries. If a battery is defective, please contact Soyer. • Do not touch any leaking fluid with bare hands. Collect the fluid and dispose of it in the correct manner. Wear goggles and protective gloves.
- Page 22 • Do not touch the burning battery, not even with protective gloves. A burning battery is extremely hot due to plasma formation! Operating Instructions Soyer Bolzenschweißtechnik...
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Page 23: Transport
Do not dispatch the battery. For the dispatch of the battery or the entire device, please contact your Soyer service technician. Please observe chapter “3. Important safety instructions for battery operation” on page 20. -
Page 24: Description Of The Bmk-8I Accu Stud Welding Device
Thanks to SRM®, the mobile BMK-8i ACCU welding device ena- bles problem-free welding, even under difficult conditions. The BMK-8i ACCU operates on the basis of a compact inverter power source and provides constant welding currents up to 300 A with extremely short welding times. -
Page 25: Stud Welding With Srm® Technology
PH-9 SRM +G stud welding guns can be connected to the BMK-8i ACCU stud welding device as standard guns. Using an adapter, the PH- 3 SRM stud welding gun can also be connected to it. 7.2.1 Stud welding with SRM® technology The welding procedure recommended by SOYER®... -
Page 26: Drawn Arc Stud Welding Technology Using Shielding Gas
Description of the BMK-8i ACCU stud welding device 7.2.2 Drawn arc stud welding technology using shielding gas For drawn arc stud welding using shielding gas, a mixed gas with 82% argon and, for example, 18% CO (e.g. Corgon®18*) is used as an aid. -
Page 27: Overview Of The Controls
Description of the BMK-8i ACCU stud welding device 7.3 Overview of the controls Figure 1: Overview of the front panel Item Designation Selection and display range with display and function keys (see chapter “7.3.1 Display and setting range” on page 29) - Page 28 Description of the BMK-8i ACCU stud welding device Figure 2: Overview of the back panel Item Designation Mains connection line Gas connection Mains switch for turning the device on/off Type designation and serial number Carrying strap Operating Instructions Soyer Bolzenschweißtechnik...
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Page 29: Display And Setting Range
Description of the BMK-8i ACCU stud welding device 7.3.1 Display and setting range [ms] > [ms] Figure 3: Display and setting range Item Designation Function selection Using the arrow keys, the following functions can be selected: • Welding current •... -
Page 30: Battery Charging And Status Indicators
Description of the BMK-8i ACCU stud welding device 7.3.2 Battery charging and status indicators Figure 4: Battery charging and status indicators Item Designation LED lights up red: The battery is being charged. LED lights up green: The battery is charged. -
Page 31: Technical Data Of The Bmk-8I Accu Stud Welding Device
Description of the BMK-8i ACCU stud welding device 7.4 Technical data of the BMK-8i ACCU stud welding device Stud welding device: Designation BMK-8i ACCU stud welding device Welding procedure Drawn arc stud welding (DS) Standard gun PH-9 SRM stud welding gun... - Page 32 Description of the BMK-8i ACCU stud welding device Battery: Designation Battery for BMK-8i ACCU stud welding device Type Lithium-ion Rated voltage 48 V Rated capacity 6.5 Ah Energy 312 Wh Subject to technical changes Operating Instructions Soyer Bolzenschweißtechnik...
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Page 33: Maximum Settings
Description of the BMK-8i ACCU stud welding device 7.4.1 Maximum settings The following table indicates the maximum welding time that can be achieved with the corresponding welding current. Impermissibly high combinations are prevent- ed by the device electronics and cannot be set. The table is thus provided for in- formation purposes only. -
Page 34: Permitted Stud Welding Guns
Description of the BMK-8i ACCU stud welding device 7.5 Permitted stud welding guns WARNING WARNING Hazards due to wrong gun Hazards for the operator may occur when a wrong welding gun is used. • Only use welding guns hereinafter permitted by Soyer. -
Page 35: Cleaning The Stud Welding Device
Description of the BMK-8i ACCU stud welding device 7.6 Cleaning the stud welding device DANGER Dangers during cleaning Improper 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 from the main power supply and secured against accidental switch- •... -
Page 36: Description Of The Srm® Stud Chuck
The standard stud chuck can hold studs with a length of up to 60 mm. For different stud diameters, different stud chucks are required. When using studs with a length > 45 mm, the stop screw must be shortened. Operating Instructions Soyer Bolzenschweißtechnik... - Page 37 Fix the stop screw with the lock nut. At a stud projection of more than 5 mm, the required trans- verse magnetic field is deflected laterally, which may result in uncontrolled SRM® welding. The adjustment is complete. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 38: Description Of The Ph-9 Srm Stud Welding Gun
The height of the lift is also decisive for the welding result. The lift height can be determined via the lift time using the stud welding device. See chapter “13.1.5 Adjusting the lift time (height of lift) in the setting mode” on page 69. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 39: Technical Data Of The Ph-9 Srm
Standard up to 60 mm, special lengths on request and possible with optional accessory Stud welding devices The gun is approved for operation on the following SOYER® stud welding devices: • BMK-8i, BMK-8i ACCU, BMK-10i • BMK-12i • BMK-16i when using the following adapters: Control cable adapter: F06770/FA... -
Page 40: Installing The Srm® Stud Chuck In Ph-9 Srm 12
Step 6: Change the gas insert according to the desired stud. Gas inserts: • Item no.: M6 = F06738 • Item no.: M8 = F06739 • Item no.: M10 = F06740 • Item no.: M12 = F06741 Operating Instructions Soyer Bolzenschweißtechnik... - Page 41 1 - 1.5 mm from the shielding gas shroud. If applicable, correct the settings of the stud chuck by moving the support. 1 - 1.5 mm Step 11: Tighten the four Allen screws. The assembly is complete. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 42: Replacing The Srm 12 Support Tube Insert Of Ph-9 Srm
When inserting it, make sure that the support tube insert and the holder surface are clean. Step 4: Tighten the two threaded pins on the support housing hand-tight. The assembly is complete. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 43: Cleaning Of The Stud Welding Gun
Welding spatters and slag can be sharp-edged. • Wear protective gloves when cleaning. We recommend the use of SOYER® separating spray in order to prevent impurities from welding spatters and slag and to simplify the cleaning process (order number M01464 ). -
Page 44: Description Of The Ph-9 Srm +G Stud Welding Gun
SRM® supply for connection with the stud welding device Gas supply for connection with the stud welding device +G support tube insert, with earth attachment Earth connection Button for two-hand release (red point on the gun’s label) Operating Instructions Soyer Bolzenschweißtechnik... -
Page 45: Technical Data Of The Ph-9 Srm
• SRM® welding procedure Stud diameter M3 - M12 (depending on the stud welding device) Stud chuck SRM® stud chuck Stud length Standard up to 60 mm, special lengths on request and possible with optional accessory Operating Instructions Soyer Bolzenschweißtechnik... -
Page 46: Operation Of The Ph-9 Srm
Technical data of the PH-9 SRM +G stud welding gun Stud welding devices The gun is approved for operation on the following SOYER® stud welding devices: • BMK-8i, BMK-8i ACCU, BMK-10i • BMK-12i • BMK-16i when using the following adapters: Control cable adapter: F06770/FA... -
Page 47: Welding With The Ph-9 Srm
Switch off the stud welding device when the gun is connected to it. Step 2: Set the stud chuck to the desired stud (see chapter “8.1 Adjust- ing SRM® stud chucks” on page 36). Step 3: Undo the union nut. Operating Instructions Soyer Bolzenschweißtechnik... - Page 48 Step 7: Slide the support with the shielding gas shroud onto the gun. Step 8: Slide the stud chuck up to the stop into the spring piston of the gun. Step 9: Hand-tighten the union nut. Operating Instructions Soyer Bolzenschweißtechnik...
- Page 49 1 - 1.5 mm from the shielding gas shroud. If applicable, correct the settings of the stud chuck 1 - 1.5 mm by moving the support. Step 11: Tighten the four Allen screws. The assembly is complete. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 50: Replacing The Srm Support Tube Insert Of Ph-9 Srm
Switch off the stud welding device when the gun is connected to it. Step 2: Loosen the Allen screw of the earth connection. Step 3: Loosen the two threaded pins on the support housing. Step 4: Remove the old support tube insert. Operating Instructions Soyer Bolzenschweißtechnik... - Page 51 Step 7: Tighten the two threaded pins on the support housing hand-tight. Step 8: Tighten the Allen screw of the earth connection with a tightening torque of 2.5 - 3 Nm. The assembly is complete. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 52: Cleaning Of The Stud Welding Gun
Welding spatters and slag can be sharp-edged. • Wear protective gloves when cleaning. We recommend the use of SOYER® separating spray in order to prevent impurities from welding spatters and slag and to simplify the cleaning process (order number M01464 ). -
Page 53: Description Of The Ph-3N Srm Stud Welding Gun
The lift height can be determined via the lift time using the stud welding device. See chapter “13.1.5 Adjusting the lift time (height of lift) in the setting mode” on page 69. The height of lift is adjusted using the dial on the gun. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 54: Technical Data Of The Ph-3N Srm Stud Welding Gun
Standard up to 60 mm, special lengths on request and possible with optional accessory Stud welding devices The gun is approved for operation on the following SOYER® stud welding devices: • BMK-8i, BMK-8i ACCU, BMK-10i (*) • BMK-12i (*) • BMK-16i Weight 4.6 kg... -
Page 55: Installing The Srm® Stud Chuck In Ph-3N Srm
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. Operating Instructions Soyer Bolzenschweißtechnik... - Page 56 If applicable, correct the settings of the stud chuck by moving the support. 1 - 1.5 mm Step 9: Fasten the support with the shielding gas shroud to the gun. The assembly is complete. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 57: Cleaning Of The Stud Welding Gun
Welding spatters and slag can be sharp-edged. • Wear protective gloves when cleaning. We recommend the use of SOYER® separating spray in order to prevent impurities from welding spatters and slag and to simplify the cleaning process (order number M01464 ). -
Page 58: Setup And Connection
The stud welding device should only be operated in a dry environment. CAUTION CAUTION Danger from welding vapours Vapours that are dangerous to health may occur, depending on the material of the workpiece and/or the welding stud. • Ensure suitable suction of welding vapours, if necessary. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 59: Connection Of The Stud Welding Device And The Stud Welding Guns
12.2.1 Mains connection After installation, connect the stud welding device to power supply using the mains plug. See chapter “7.4 Technical data of the BMK-8i ACCU stud welding device” on page 31. When switching on the device, all LEDs on the front panel light up briefly. -
Page 60: Connecting The Stud Welding Gun
The gas connection on the back panel is used to supply the stud welding device with gas via a pressure reducer (pressure reducing valve not included in the scope of delivery). The maximum permissible operating value for the shielding gas quantity is 12 l/min. Operating Instructions Soyer Bolzenschweißtechnik... - Page 61 Gas flow meter [l/min] (pressure reducing valve) Shut-off valve for the gas connection hose of the stud welding device Gas connection hose of the stud welding device Valve for regulating the gas flow rate (maximum permissible gas quantity: 12 l/min) Operating Instructions Soyer Bolzenschweißtechnik...
- Page 62 Use the regulating valve to set a shielding gas flow rate of approx. 4 - 5 l/min. Step 5: Connect the shielding gas hose of the gun to the stud welding device. The gas supply is established. Operating Instructions Soyer Bolzenschweißtechnik...
- Page 63 • Protect the gas supply against access by unauthorised persons. The following shielding gas mixtures are recommended: • 82% argon and 18% CO (preferably) • 90% argon and 10% CO • 85% argon and 15% CO Operating Instructions Soyer Bolzenschweißtechnik...
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Page 64: Settings
The parameters to be set on the stud welding device depend, among others, on the following influencing factors: • Material of the workpiece • Thickness of the workpiece • Material of the welding stud • Diameter of the welding stud Operating Instructions Soyer Bolzenschweißtechnik... -
Page 65: Support Tables For Device Settings
Gas pre-flow time [s] Lift time/height of lift Required height of lift approx.: 1 - 1.5 mm Lift time approx. [ms] 12.5 10.0 The values were determined on a metal sheet with a thickness of 2 mm. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 66: Adjusting Welding Current And Welding Time
If selected correctly, the [ms] > LED lights up. [ms] Step 5: Use the +/- keys to set the desired value for the welding time on the display. The welding time is adjusted. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 67: Adjusting/Deactivating Srm® Current
The SRM® current can be adjusted from 0 - 1500 mA (displayed in A) in increments of 50 mA (0.05 A). When “0” has been set, SRM® is deactivated. The SRM® current is adjusted. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 68: Adjusting The Gas Pre-Flow Time
If selected correctly, the [ms] > LED lights up. [ms] Step 3: Use the +/- keys to set the desired value (1-5 s) for the gas pre-flow time on the display. The gas pre-flow time is adjusted. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 69: Adjusting The Lift Time (Height Of Lift) In The Setting Mode
Switch on the device. Step 2: Equip the gun with a welding stud. Step 3: Use the arrow keys ↑↓ to select the position for the lift test. If selected correctly, the [ms] > LED lights up. [ms] Operating Instructions Soyer Bolzenschweißtechnik... - Page 70 Notes on the setting mode • The adjustment can be repeated as often as needed. To prevent the magnetic coil from overheating, however, it is necessary to wait for approx. one second between two test lifts. Operating Instructions Soyer Bolzenschweißtechnik...
- Page 71 • To be able to test the lift, the gun must rest flush on the workpiece. • To release the gun, two-hand operation must be activated. To this end, all three release buttons must be pressed. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 72: Welding Operation
Insert the appropriate stud chuck and a welding stud (see chap- ter “8. Description of the SRM® stud chuck” on page 36). Only use SOYER® welding studs. Step 4: To check the battery charging status, press the release button of the welding gun. - Page 73 By doing so, widening or damaging the stud chuck is avoided. For welding with the PH-9 SRM +G gun, please observe chapter “10.2 Operation of the PH-9 SRM +G” on page 46. The welding process is finished. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 74: Notes On Checking The Quality Of The Weld
Welding operation 14.2 Notes on checking the quality of the weld If the SOYER® stud welding equipment is handled correctly and the correct materials are selected, the strength of the welding joint (welding zone) is always higher than the strength of the stud or the base material. -
Page 75: 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 cannot be switched on and used by unauthorised persons. Close the valves at the gas supply. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 76: Welding Defects And Their Causes
The connection plug or the connection socket of the device are damaged. • Have the plug or socket replaced by the SOYER® customer service. Both earth cables are not or not properly connected or the earth clamps are not attached to the workpiece. - Page 77 The control of the device or of the welding gun is defective. (The stud does not lift, even though the height of lift is set correctly.) • Contact the SOYER® customer service. The stud lifts, but the The lift is too high.
- Page 78 You have used low-quality studs with inaccurate dimensions or a poor surface finish. • Only use SOYER® welding studs. The welding time and/or the gas flow are not set correctly. • Readjust the welding time and/or the gas flow.
- Page 79 Grind the surface. The battery charging status is too low. • Check the battery charging status. Fuse in the device defective. • Contact the customer service. Stud thread scorched. Stud chuck worn. • Exchange stud chuck. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 80: Maintenance And Repair
Maintenance and repair 15. Maintenance and repair Maintenance and repair of the stud welding device and the stud welding guns should only be performed by Heinz Soyer Bolzenschweißtechnik GmbH or authorised specialists. 16. Service If servicing is required, please contact: Heinz Soyer Bolzenschweißtechnik GmbH... - Page 81 Operating Instructions Soyer Bolzenschweißtechnik...
- Page 82 Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 82237 Wörthsee Tel.: 0049-8153-885-0 Mail: info@soyer.de...
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