Related Manuals for Soyer BMK-10i
Summary of Contents for Soyer BMK-10i
- Page 1 Operating Instructions Stud Welding Device BMK-10i GB: English ersion Read these operating instructions before starting any work! Date of issue: 08.2017 Doc.ID: P00259 www.soyer.com...
- Page 3 PH-9 SRM Stud welding gun PH-3N SRM Operating manual Document no.: P00259, 08-2017, translation of the original German manual (P00159) All information in this document is the property of Heinz Soyer Bolzenschweißtechnik GmbH. Revision status Document Created / modified Editor...
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Page 4: Table Of Contents
Overview of the controls ....................... 23 6.3.1 Display and setting area ....................25 Technical data of the BMK-10i stud welding device ............26 Permitted stud welding guns ....................27 Cleaning the stud welding device ..................28 Description of the SRM stud chuck................... 29 Setting the SRM stud chuck .................... - Page 5 Notes on checking the quality of the weld ................67 13.2.1 Visual inspection ......................67 13.3 Switching off the device ....................... 68 13.4 Weld defects and their causes ..................... 69 Maintenance and repair ...................... 73 Service ..........................73 Warranty conditions ......................73 Operating manual Soyer Bolzenschweißtechnik...
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Page 6: General Information
PH-3N SRM Registered trademarks The following terms in this manual are marked with registered trademarks: ® SRM stands for magnetic field stud welding and refers to stud welding in a radially symmetrical magnetic field. ® SOYER Developments/technologies of Soyer GmbH. -
Page 7: Abbreviations And Definitions
The devices are built according to the generally accepted codes of practice. Please note that significant modifications to the device can void the declaration of conformity. In addition, the manufacturer warranty coverage may be rendered invalid. Operating manual Soyer Bolzenschweißtechnik... - Page 8 Stud welding device Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 82237 Wörthsee CE Declaration of Conformity We herewith declare that the machine described in the following and the version available on the market correspond in design and construction to the safety and health requirements of the listed guidelines and standards.
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Page 9: Manufacturer
Manufacturer The manufacturer of the devices is: Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 82237 Wörthsee Tel.: 0049-8153-885-0 Fax: 0049-8153-8030 Mail: info@soyer.de Web: www.soyer.de, www.soyer.com Instruction, training ® SOYER offers optional and individual instruction in the operation of the devices. -
Page 10: Important Safety Instructions
Do not touch or open, danger for unauthorised persons. Danger for persons with a heart pacemaker or other medical implants. The info sign is not a safety alert. It indicates important and useful information on the subject. Operating manual Soyer Bolzenschweißtechnik... -
Page 11: General Safety Instructions
Starting the device with defective protection equipment is not allowed. Repair or replace faulty protective equipment immediately. Unwanted operation by a third party must be prevented. Operating manual Soyer Bolzenschweißtechnik... - Page 12 Work on electrical or electronic components must only be carried out by electrical specialists from Soyer Bolzenschweißtechnik. Before working on the stud welding device, the mains switch of the device must be switched off and the mains plug of the stud welding device disconnected.
- Page 13 Always use personal protective equipment. Fire hazards from hot welding spatter Welding spatter or hot workpieces occurring due to the welding process can result in fire hazards. Do not store any inflammable and combustible materials in the welding area. Operating manual Soyer Bolzenschweißtechnik...
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Page 14: Safety Instructions For The Working Method
If the gun is not put on properly or the gun settings are incorrect, a flash can occur during welding. Do not look directly into the flash. The gun carries out lifting movements during the welding process. Do not hold the gun tight in the area of moving parts. Operating manual Soyer Bolzenschweißtechnik... -
Page 15: Personal Protection Equipment
Safety shoes Welding spatter occurs during welding. Wear suitable, non-combustible, heat-resistant safety shoes. Hearing protection Depending on the welding device and the welding application, relatively loud welding noises can occur. Wear suitable hearing protection. Operating manual Soyer Bolzenschweißtechnik... -
Page 16: Intended Use Of The Stud Welding Device
Intended use of the stud welding device Pins and threaded studs from M3 – M10 and M12 HZ-1R (M6 to M10 preferred) made ® of steel and stainless steel can be welded using the SOYER BMK-10i stud welding device. Special studs or diameters on request. -
Page 17: Incorrect Use
If the welders have to be qualified for certification of welding, the DIN EN ISO 14555 and DIN EN ISO 14732 standards must be observed. Operating manual Soyer Bolzenschweißtechnik... - Page 18 The following basically applies: 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 devices of Soyer Bolzenschweißtechnik GmbH must only be opened by ® ®...
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Page 19: Transport
Local environmental guidelines for disposal must be complied with. Substances that are hazardous to water and the environment must be disposed of in accordance with legal regulations. Materials must be separated according to regulations where applicable. Operating manual Soyer Bolzenschweißtechnik... -
Page 20: Description Of The Bmk-10I Stud Welding Device
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 compact inverter current source and delivers a constant welding current up to 600 A with extremely short welding times. The rectified mains voltage is converted into a high frequency voltage with a frequency of 75 kHz by an Insulated Gate Bipolar Transistor-based (IGBT-based) inverter. -
Page 21: Stud Welding With Srm Technology
The PH-9 SRM and PH-9 SRM +G stud welding guns or the PH-3 SRM stud welding gun, with an adapter, can be connected as standard guns to the BMK-10i stud welding device. ® 6.2.1 Stud welding with SRM technology ®... -
Page 22: Drawn Arc Stud Welding Technology With Shielding Gas
Further information on this subject can be found at www.soyer.com. Operating manual Soyer Bolzenschweißtechnik... -
Page 23: Overview Of The Controls
6.3.1 “Display and setting area” on page 25) Shielding gas connection of the gun, coupling socket KD 1/4 Control cable connection of the gun Welding cable connection of the gun Connection of the earth cable Operating manual Soyer Bolzenschweißtechnik... - Page 24 Figure 2: Overview of the back of the device Item Designation Type plate Fuse element with fuse 1 AT Gas connection Carrying belt Mains switch for switching the device on/off Mains connection cable Operating manual Soyer Bolzenschweißtechnik...
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Page 25: Display And Setting Area
• Trigger button of the gun is pressed • Gun is placed on the workpiece and ready for welding • SRM is active • Gas preflow is active The LED next to the active operating state lights up. Operating manual Soyer Bolzenschweißtechnik... -
Page 26: Technical Data Of The Bmk-10I Stud Welding Device
Technical data of the BMK-10i stud welding device Designation BMK-10i stud welding device Welding process Drawn arc stud welding (DA) Standard gun PH-9 SRM stud welding gun and PH-9 SRM ® Welding area SOYER threaded studs from M3 - M10 and M12 HZ- 1R (M6 to M10 preferred) HZ-1 and MF types or nails Ø... -
Page 27: Permitted Stud Welding Guns
Only use the welding guns from SOYER permitted in the following. 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 Comments PH-9 SRM... -
Page 28: Cleaning The Stud Welding Device
Improper cleaning can lead to damage of the device. Cleaning agents must not get into the device. Do not use aggressive agents for cleaning. The frequency of cleaning depends on the conditions in which the stud welding device is used. Operating manual Soyer Bolzenschweißtechnik... -
Page 29: Description Of The Srm Stud Chuck
The standard stud chuck can hold studs up to a length of 60 mm. Different stud diameters require different stud chucks. When using studs with a length > 45 mm, the end stop screw must be shortened. Operating manual Soyer Bolzenschweißtechnik... - Page 30 Step 4: Fix the end screw with the locknut. If the stud protrusion is more than 5 mm, the required transverse magnetic field is deflected sideways which can lead to uncontrolled SRM welding. The setting is complete. Operating manual Soyer Bolzenschweißtechnik...
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Page 31: Description Of The Ph-9 Srm Stud Welding Gun
The lift height can be determined 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. Operating manual Soyer Bolzenschweißtechnik... -
Page 32: Technical Data Of The Ph-9 Srm
SOYER stud welding devices: BMK-8i BMK-10i BMK-12i BMK-16i when using an 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 Operating manual Soyer Bolzenschweißtechnik... -
Page 33: Installing The Srm Stud Chuck In Ph-9 Srm
Item no.: M6 = F06738 Item no.: M8 = F06739 Item no.: M10 = F06740 Item no.: M12 = F06741 Step 7: Slide the tripod with the shielding gas cap onto the gun. Operating manual Soyer Bolzenschweißtechnik... - Page 34 1 - 1.5 mm out of the shielding gas cap. If necessary, correct the setting of the stud chuck by shifting the tripod. 1 - 1.5mm Step 11: Tighten the four socket head screws. Assembly is complete. Operating manual Soyer Bolzenschweißtechnik...
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Page 35: Replacing The Srm
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. Step 4: Hand-tighten the two threaded pins on the tripod housing. Assembly is complete. Operating manual Soyer Bolzenschweißtechnik... -
Page 36: Cleaning The Welding Gun
Welding spatter and slag can have sharp edges. Wear protective gloves when cleaning. To prevent impurities from welding spatter and slag and to simplify cleaning, ® we recommend using SOYER release spray (order number M01464). Operating manual Soyer Bolzenschweißtechnik... -
Page 37: Description Of The Ph-9 Srm +G Weld 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 the two-hand triggering (red point on the gun sticker) Operating manual Soyer Bolzenschweißtechnik... - Page 38 The gas insert serves to optimise the gas flow and insulate the stud chuck from the shielding gas cap. The PH-9 SRM +G stud welding gun may only be operated with the stud welding devices specified in the technical data. Operating manual Soyer Bolzenschweißtechnik...
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Page 39: Technical Data Of The Ph-9 Srm
The welding process may be started unintentionally if the trigger buttons are faulty or bridged. This may cause burns. Do not operate the gun with faulty or bridged protection equipment. Operating manual Soyer Bolzenschweißtechnik... -
Page 40: Welding With The Ph-9 Srm +G
Always make sure that contact to the workpiece is clean and that the attachment is fully seated on the workpiece. All three trigger buttons must always be pressed simultaneously to trigger the welding process. Operating manual Soyer Bolzenschweißtechnik... -
Page 41: Installing The Srm Stud Chuck For The Ph-9 Srm +G
Gas inserts • Item no.: M6 = F06738 •Item no.: M8 = F06739 •Item no.: M10 = F06740 •Item no.: M12 = F06741 Step 7: Slide the tripod with the shielding gas cap onto the gun. Operating manual Soyer Bolzenschweißtechnik... - Page 42 1 - 1.5 mm out of the shielding gas cap. If necessary, correct the setting of the stud chuck by shifting the tripod. 1 - 1.5mm Step 11: Tighten the four socket head screws. Assembly is complete. Operating manual Soyer Bolzenschweißtechnik...
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Page 43: Replacing The Srm Support Tube Insert With The Ph-9 Srm +G
Switch off the stud welding device if the gun is connected to the stud welding device. Step 2: Undo the earth connection socket head screw. Step 3: Undo the two threaded pins on the tripod housing. Step 4: Remove the old support tube insert. Operating manual Soyer Bolzenschweißtechnik... - Page 44 Step 7: Hand-tighten the two threaded pins on the tripod housing Step 8: Tighten the earth connection socket head screw with a tightening torque of 250 - 300 cN. Assembly is complete. Operating manual Soyer Bolzenschweißtechnik...
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Page 45: Cleaning The Stud Welding Gun
Welding spatter and slag can have sharp edges. Wear protective gloves when cleaning. To prevent impurities from welding spatter and slag and to simplify cleaning, ® we recommend using SOYER release spray (order number M01464). Operating manual Soyer Bolzenschweißtechnik... -
Page 46: Description Of The Ph-3N Srm Stud Welding Gun
The lift height can be determined 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 the adjusting wheel on the gun. Operating manual Soyer Bolzenschweißtechnik... -
Page 47: Technical Data Of The Ph-3N Srm Stud Welding Gun
The gun is approved for operation on the following ® SOYER stud welding devices: • BMK-8i (*) • BMK-12i (*) • BMK-16i Weight 1.3 kg without cable Subject to technical changes (*) With adapter plug, see technical data of stud welding device. Operating manual Soyer Bolzenschweißtechnik... -
Page 48: Installing The Srm Stud Chuck With Ph-3N Srm
Step 5: If there is still a stud chuck in the gun, remove it. Step 6: Slide the stud chuck to the end stop in the spring piston of the gun. Step 7: Hand-tighten the union nut. Operating manual Soyer Bolzenschweißtechnik... - Page 49 1 - 1.5 mm out of the shielding gas cap. If necessary, correct the setting of the stud chuck by shifting the tripod. 1 - 1.5 mm Step 9: Fasten the tripod with the shielding gas cap onto the gun. Assembly is complete. Operating manual Soyer Bolzenschweißtechnik...
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Page 50: Cleaning The Welding Gun
Welding spatter and slag can have sharp edges. Wear protective gloves when cleaning. To prevent impurities from welding spatter and slag and to simplify cleaning, ® we recommend using SOYER release spray (order number M01464). Operating manual Soyer Bolzenschweißtechnik... -
Page 51: Setup And Connection
The stud welding device must only be operated in dry rooms. Danger from welding vapours Health threatening vapours can occur depending on the material of the workpiece and/or welding stud. Where necessary, ensure suitable extraction of the welding vapours. Operating manual Soyer Bolzenschweißtechnik... -
Page 52: Connection Of The Stud Welding Device And The Stud Welding Guns
11.2.1 Mains connection After installation, connect the stud welding device to the power supply using the mains plug. To do so, observe chapter “6.4 Technical data of the BMK-10i stud welding device” on page 26. When switching on the device, all LEDs on the front panel light up briefly. -
Page 53: Connecting The Stud Welding Gun
The gas connection on the back of the device is used for supplying gas to the stud welding device via a pressure reducer (pressure reducing valve not included in the scope of delivery). The maximum permissible operating value for the shielding gas amount is 12 l/min. Operating manual Soyer Bolzenschweißtechnik... - Page 54 Valve for regulating the gas flow rate (maximum permissible gas amount: 12 l/min) The following shielding gas mixtures are recommended: 82% argon and 18% CO (preferred) 90% argon and 10% CO 85% argon and 15% CO Operating manual Soyer Bolzenschweißtechnik...
- Page 55 Use the regulating valve to set a shielding gas flow rate of approx. 4 - 5 l/min. Step 5: Plug the shielding gas hose of the gun into the stud welding device. The gas supply is established. Operating manual Soyer Bolzenschweißtechnik...
- Page 56 Carry out all necessary, prescribed checks of the gas cylinder, fittings and lines. Safeguard the gas supply against unauthorised access. The following shielding gas mixtures are recommended: 82% argon and 18% CO (preferred) 90% argon and 10% CO 85% argon and 15% CO Operating manual Soyer Bolzenschweißtechnik...
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Page 57: 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 Operating manual Soyer Bolzenschweißtechnik... -
Page 58: Help Tables For Device Setting
12.1.1 Help tables for device setting The values in the table below can be useful as guide values for a first test weld. How the respective settings are made is explained in later chapters. BMK-10i SRM welding parameters setting aid PH-9 SRM and PH-9 SRM... -
Page 59: Setting The Welding Current And The Welding Time
The LED lights up if the selection is correct. Step 5: Use the +/- keys to set the required value for the welding time on the display. The welding time has been set. Operating manual Soyer Bolzenschweißtechnik... -
Page 60: Setting/Deactivating The Srm Current
SRM current on the display. The SRM current is adjustable from 0 - 1500 mA (display in A) in 50 mA steps (0.05 A). If the setting is "0", SRM is deactivated. The SRM current has been set. Operating manual Soyer Bolzenschweißtechnik... -
Page 61: Setting The Gas Preflow Time
The LED lights up if the selection is correct. Step 3: Use the +/- keys to set the required value (1-5 s) for the gas preflow time on the display. The gas preflow time has been set. Operating manual Soyer Bolzenschweißtechnik... -
Page 62: Setting The Lift Time (Height Of Lift) In The "Setup" Mode
Switch on the device. Step 2: Fit the gun with a welding stud. Use the ↑↓ arrow keys to select the Step 3: position for the lift test. The LED lights up if the selection is correct. Operating manual Soyer Bolzenschweißtechnik... - Page 63 (green LEDs). Notes on "Setup" mode The setup process can be repeated as often as required. However, to avoid the magnetic coil overheating, maintain a waiting time of approx. one second between test strokes. Operating manual Soyer Bolzenschweißtechnik...
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Page 64: Notes On The Ph-9 Srm +G Welding Gun
The lift can only be tested when the gun is positioned flush on the workpiece. Two-hand operation must be activated to trigger the gun. All three trigger buttons have to be pressed to do this. Operating manual Soyer Bolzenschweißtechnik... -
Page 65: Welding Operation
Before operating the stud welding device, observe chapter “2. Important safety instructions” on page 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. - Page 66 This prevents the stud chuck widening and becoming damaged. For welding with the PH-9 SRM +G gun, please consult chapter “9.2 Operation of the PH-9 SRM12+G” on page 39. The welding process is now complete. Operating manual Soyer Bolzenschweißtechnik...
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Page 67: Notes On Checking The Quality Of The Weld
The weld bead is weak and unevenly formed. Poor weld joint, e.g. through arc blow effect, welding gun shaken or applied at a slant. The stud flange is not fully welded and has visible defects. Undercuts are visible. Operating manual Soyer Bolzenschweißtechnik... -
Page 68: Switching Off 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 by unauthorized persons. Close the shut-off valves at the gas supply. Operating manual Soyer Bolzenschweißtechnik... -
Page 69: Weld Defects And Their Causes
13.4 Weld defects and their causes The most common weld defects, their possible causes and how to troubleshoot them are described in the following. If the fault cannot be remedied as described, please contact Heinz Soyer Bolzenschweißtechnik GmbH. Faults Possible cause and troubleshooting ... - Page 70 Lift is too large. current is not ignited. Set the lift in accordance with the operating manual for your welding gun. Gas pressure is too high. Set the gas pressure to the specified value. Operating manual Soyer Bolzenschweißtechnik...
- Page 71 Very heavy spark Main current duration set too long. formation, stud flange almost melted Re-adjust the time for the main current duration according to the away. table. Welding current set too high. Re-adjust the welding current. Operating manual Soyer Bolzenschweißtechnik...
- Page 72 Grind off the surface. Faulty mains supply. Check the mains supply fuses. Fuse in the device is defective. Contact customer service. Welding stud thread Stud chuck is worn out. is scorched. Replace the stud chuck. Operating manual Soyer Bolzenschweißtechnik...
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Page 73: Maintenance And Repair
14 Maintenance and repair The stud welding device and the stud welding guns must only be maintained and repaired by Heinz Soyer Bolzenschweißtechnik GmbH or its authorised specialists. 15 Service In the event of service, please contact: Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14... - Page 74 Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 82237 Wörthsee Tel.: 0049-8153-885-0 Mail: info@soyer.de www.soyer.com www.srm-technology.com...