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Summary of Contents for Soyer BMK-12i
- Page 1 Operating Instructions BMK-12i Stud welding inverter for drawn arc welding with SRM technology GB: English Version Read these operating instructions before starting any work! Doc.ID: P00256 Date of issue: 10.2017 www.soyer.de...
- Page 3 Order No. Code designation Note P01360 BMK-12i Mains voltage 3 x 400 V Heinz Soyer Bolzenschweißtechnik GmbH www.soyer.de Inninger Straße 14 | 82237 Wörthsee | Tel.: +49 8153 8850 | Fax: +49 8153 8030 | E-mail: info@soyer.de |...
- Page 4 ® Congratulations on purchasing the BMK-12i SOYER stud welding inverter. ® You have made an excellent choice. Your BMK-12i SOYER stud welding inverter was specially developed for the high-speed fastening of SOYER ® HZ-1 weld studs on metallic, weldable workpieces by means of the patented SRM technology.
- Page 5 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 6: Table Of Contents
Table of contents Safety instructions ........................ 8 Description of reference signs in the operating instructions ..........10 Staff qualification and training ....................11 Dangers in the case of non-compliance with safety instructions ......... 11 Before starting to weld......................11 Working with the stud welding inverter ................ - Page 7 Start-up of the PH-9 SRM stud welding gun ................ 36 Notes on the "Lifting test" operation mode ................41 SRM welding operation ......................41 5.6.1 Stud welding with shielding gas ..................42 Error messages and notes ....................43 5.7.1 Gun connection ........................ 43 5.7.2 Increased temperature .....................
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Page 8: Safety Instructions
1 Safety instructions These safety precautions are for your safety. General safety instructions Take part in a training programme. Read and follow all safety precautions listed below and all chapters of this manual before starting to weld. Non-compliance with the safety precautions can result in personal injuries or death. - Page 9 Fumes and gases can cause damage to your health Fumes and suspended/floating particles may be generated during welding. Beware of fumes detrimental to health, particularly when using surface treated materials. Please also observe the safety regulations applicable for your country. Do not inhale fumes and gases.
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Page 10: Description Of Reference Signs In The Operating Instructions
Description of reference signs in the operating instructions The non-observance of safety instructions such as pictographs and warning words can cause damage to persons. The safety instructions of this operating manual describe the following. Safety instructions Danger! Immediate hazards which could result in serious personal injuries or loss of life. -
Page 11: Staff Qualification And Training
Roll up the cables without buckling them. • Prevent the welding equipment being operated by unauthorized personnel. • Check welding cables and connections of the welding equipment for damage such as burn-off, ® mechanical wear etc. and have damaged parts replaced by the SOYER customer service. -
Page 12: General
2 General The following should be principally observed... With the BMK-12i stud welding inverter you have purchased a product which • is state-of-the-art technology • fully complies with the current safety requirements • features a unique compact design • ensures high performance. -
Page 13: Marketing And Service
Telephone +49 8153 8850 Telefax +49 8153 8030 www.soyer.de info@soyer.de Information on the documentation The following operating instructions are supplied with the BMK-12i stud welding inverter: • Operating instructions for BMK-12i Order No.: P00256 2.4.1 Information on the operating instructions Legal relationship We point out that the contents of these operating instructions are neither part of any former or existing arrangement, pledge or legal relationship nor have they been designed to modify the latter. -
Page 14: Description Of Welding Equipment
3 Description of welding equipment Description The BMK-12i stud welding inverter has been designed for mobile use. As a result of intensive ® development work in the area of inverter technology, the SOYER BMK-12i defines a completely new equipment class. The equipment operates on the basis of a compact inverter source of electricity and provides constant welding currents up to 800 A with extremely short welding periods. -
Page 15: Drawn Arc Stud Welding Technology Using Shielding Gas
The stud comes into contact The arc is guided through the The stud immerses into the with the workpiece and is spiral-shaped magnetic field very flat penetration zone and raised. The arc is triggered. and fully melts both join parts. is inseparably connected. -
Page 16: Technical Data
Technical data Designation BMK-12i Welding process Drawn arc stud welding (DS) ® SOYER threaded studs, DIN EN ISO 13918 from Welding range M3 – M10 RD (MR) or Ø 2 – 10 mm or M6 – M12 HZ-1 Steel, stainless steel and heat-resistant steel (aluminium... -
Page 17: Start-Up
4 Start-up Installation of equipment The top of the BMK-12i stud welding inverter is equipped with a carrying handle. CAUTION The carrying handle is intended for transport by hand only. Never pull ropes through this handle to lift the welding equipment by means of a crane to the installation site. -
Page 18: Front And Rear View
Front and rear view Front view of BMK-12i Rear view of BMK-12i... -
Page 19: Operating Elements
4.2.1 Operating elements • ON/OFF switch The equipment is activated by moving the rocker switch on the rear of the equipment into the "I" position. The operating status is indicated on the activated display. The equipment is deactivated by moving the rocker switch on the rear of the equipment into the "O"... -
Page 20: Description Of The Operating Modes And Parameters
4.2.3 Description of the operating modes and parameters Operating modes Several operating modes are available which have been allocated to specific parameter lines. The "Operation" operating mode, which is set for regular welding work, is available on the Main Parameters page, in the Program, Main current (A) and Main current time (ms) lines. When selecting the "Gas pre-flow time (ms)"... - Page 21 System settings Menu item Description Mode Page navigation with the keys 6.1 and System settings Stand-by Setting of the display background Background illumination illumination 50 up to 100 % Stand-by Software version Version number of the software Stand-by Please note: The program positions 1 - 10 can be freely assigned by the user.
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Page 22: Overview Of Menu Items
4.2.4 Overview of menu items... -
Page 23: Description Of Symbols
4.2.5 Description of symbols Symbol Description Function Symbol lights up when pressing release button of welding "Release" gun. Symbol lights up when earth terminal is connected and stud "Stud on Workpiece" touches the workpiece. Symbol lights up when shielding gas valve is open. "Gas active"... -
Page 24: Preparation For Start-Up
Preparation for start-up Connect the stud welding gun and earth cable to the welding equipment prior to start-up. 4.3.1 Earth connection • Attach earth cable to earth cable connector marked with the EARTH/GROUND symbol and lock by turning to the right until stop. •... -
Page 25: Connection Of Stud Welding Gun
Examples for various earth connections and possible effects: Balanced earth connection Ideal condition: The stud is located in the centre of both earth connections. Unbalanced earth connection Arc is deflected to the side where there is less current density. Additional masses disturb arc symmetry. 4.3.2 Connection of stud welding gun •... -
Page 26: Gas Supply
Example for gas supply. Deviations are possible depending on the manufacturer 1 Gas cylinder 5 Shut-off valve 2 Hand wheel (left = open, right = closed) 6 Gas supply hose 3 Manometer for indicating the gas 7 Control cock for gas flow rate cylinder‘s pressure Screwing in increases the flow Screwing out decreases the flow... -
Page 27: Power Supply
4.4.2 Power supply Use the mains cable to connect the welding equipment to the power supply. MORTAL DANGER Ensure correct connected loads for electrical connections as indicated on the type plate of the welding equipment. Starting the welding equipment After switching on the welding equipment, an animation appears and the welding equipment carries out a self-test which runs in the background. -
Page 28: Operating Mode "Lift Test
4.6.2 Operating mode "Lift Test" This operation mode enables you to adjust and check the lift of the gun. • Select the operating mode "Lift Test". • Insert a stud into the welding gun. • Check the immersion depth of the stud and set it according to the operating instructions of the welding gun. -
Page 29: Operating Mode "Gas Test
(see DVS guideline, Part 1, "Quality assurance of stud welding joints"). The welding parameters were determined with the BMK-12i welding equipment and the PH-9 SRM stud welding gun using a lift adjustment of about 2.0 mm. A steel plate with a thickness of 5 mm ®... - Page 30 Table for welding parameters For weld studs as per DIN EN ISO 13 918 ~2.5 ~3 ~2.7 ~3.5 ~2.8 ~4 ~4.2 ~3.2 ~4.5 ~1.5 ~1 ~1.6 ~1.2 ~2 ~1.3 ~2.3 ~1.5 ~2.6 ~1.8 ~ 120 ~ 200 ~ 250 ~ 350 ~ 200 ~ 250 ~ 350...
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Page 31: Operation
5 Operation Brief description This section is designed to provide you with a quick start into the welding operation. For detailed information, please refer to chapter 5.2. NOTE The relevant accident prevention and safety regulations must be complied with when operating the welding equipment. - Page 32 • Press the push button. The LED "Release" lights up and the stud welding process is started. The active functions are displayed by the LEDs: Start button / Inert gas / SRM. During the welding process, keep the gun steady. After completion of the welding process, remove gun vertically from the welded stud to prevent widening and damaging of the stud chuck.
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Page 33: Basic Setting Of The Srm Stud Chuck
Basic setting of the SRM stud chuck SRM stud chucks are available in the following different sizes: M8, Ø 9 mm, M10, Ø 10.8 mm, M12 and M14. The SRM stud chuck has been specifically designed for the PH-3N and PH-9 stud welding guns. For different stud diameters, different stud chucks are required. -
Page 34: Basic Setting Of The Srm Nut Holder
Basic setting of the SRM nut holder The SRM nut holder is available for M6, M8, M10 and M12 nuts. The SRM nut holder has been specifically designed for the PH-3N and PH-9 stud welding guns. The SRM nut holder can be installed directly. - Page 35 Note for nut welding on punched sheet metal Use our weld nuts with centring inserts for punched sheet metal. Thanks to our centring insert, the weld nut is welded centrally over a hole. When using a template or other equipment, it is not necessary to use the centring insert.
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Page 36: Start-Up Of The Ph-9 Srm Stud Welding Gun
Start-up of the PH-9 SRM stud welding gun NOTE: The PH-3N SRM welding gun is only suitable for stud sizes M6 - M12 and weld nut sizes M8, M10 and M12! TIP: The PH-3N SRM welding gun is provided with a standard gas shroud. Use inert gas to avoid the formation of pores and to optimise the collar formation. - Page 37 If necessary, prepare the ground connection (use protective goggles). The contact areas for the ground connection must be metallically bright. TIP: You can improve the transition resistances if both sides of the locking pliers have contact with the ground. NOTE: To facilitate the installation of the stud chuck or nut holder, move or dismantle the support together with the gas shroud.
- Page 38 How to correct the stud protrusion Insert the weld stud / weld nut into the chuck / nut holder and push it firmly until it comes to a stop. Use Allen wrench (size 3) to loosen the four Allen screws. Move support until a stud protrusion of approx.
- Page 39 Switch stud welding equipment on with the mains switch. Please observe the safety instructions! Adjusting and checking the height of lift The height of lift is the distance by which the stud is lifted from the workpiece during the welding process. This distance is required for igniting the arc.
- Page 40 Position welding gun vertically on the workpiece (at a 90- degree angle to the workpiece). Check the selected parameters. Start the welding process by pressing the trigger. During the welding process, keep the gun steady. After completion of the welding process, remove gun vertically from the welded stud to prevent widening and damaging of the stud chuck.
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Page 41: Notes On The "Lifting Test" Operation Mode
Notes on the "Lifting test" operation mode The lifting test allows for the activation of the gun’s lifting magnet thus controlling the setting. Proceed as follows: • Provide ground connection to the workpiece, connect welding gun. • Mount stud chuck on the welding gun and insert weld stud into stud chuck. •... -
Page 42: Stud Welding With Shielding Gas
The setting procedure for further welding parameters such as stud protrusion and lift is similar to that of stud welding without SRM. The current intensity (mA) of the radial-magnetic field is altered via the SRM parameters. SRM = 0 indicates that SRM is not active SRM = 500 current for magnetic field 500 mA Range: 0 –... -
Page 43: Error Messages And Notes
• Press trigger switch. • When welding with shielding gas, the welding point is rinsed during the welding process as well as before and after welding for the period adjusted. • The LED "Gas valve open" indicates that the gas valve is open. Error messages and notes 5.7.1 Gun connection... -
Page 44: Phase Failure / Overvoltage / Undervoltage
6 Quality control (stud welding) General instructions ® Provided the SOYER welding equipment is correctly used and the materials are appropriately selected, the strength of the welding joint (welding zone) will always be stronger than that of the stud or base material. -
Page 45: Test Execution
Test execution 6.2.1 Production of samples The dimensions of the test piece must be sufficient to carry out all tests. The thickness of the test piece must be the same as used in later production. Use the same welding positions and edge distances as on the component to be welded later. -
Page 46: Bend Test
6.2.3 Bend test The bend test is a simple work test which serves to roughly check the setting values selected. The welding zone is subjected to undefined tension, pressure and bending. A minimum of 3 studs are welded and bent by means of a tube slipped over the stud. The test is successful when no superficial fissure or fracture is detected in the welding zone. -
Page 47: Maintenance
WARNING Our BMK-12i is a highly integrated, state-of-the-art stud welding equipment. The service personnel are required to meet special qualifications. If the housing of the welding equipment is opened by untrained service personnel, the proper function of the welding equipment can no longer be guaranteed. -
Page 48: Replacement Of Components
The following list of errors, their causes and remedies is designed to help you eliminate any trouble ® immediately on the spot. If you cannot eliminate the trouble, please contact the SOYER customer service responsible for your area or Heinz Soyer Bolzenschweißtechnik GmbH. -
Page 49: Malfunctions
Connect cables and/or gas hose properly or check for damage. Replace if necessary. Connecting plug or socket of welding equipment is burnt down. Have plug or socket replaced by SOYER ® customer service. Both earth cables are not properly connected or not connected at all. Earth clamps are not attached to the workpiece. - Page 50 Refer to the operating instructions of your welding gun to set the height of lift or depth of immersion correctly. You have used low-quality studs with inaccurate dimensions or poor surface finish. Only use SOYER ® welding studs as per DIN EN ISO 13918. Welding time and/or gas flow incorrectly set.
- Page 51 Stud not welded with Main current time too short. Readjust time for main current duration according to the table. total flange surface, deficient weld joint Poor earth connection Check earth cables and earth clamps for tight fit, tighten if necessary. strength.
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Page 52: Transport And Storage
The welding equipment is robustly designed and has a two-piece metal housing with front and rear panel. Owing to electronic components it should be ensured, however, that transport is free from vibrations. The BMK-12i welding equipment has a carrying handle for easy transport and mobile use over short distances. NOTE Prevent unauthorized use of the welding equipment by children and unqualified personnel. -
Page 53: List Of Standards And Guidelines
11 List of standards and guidelines • 2014/35/EU Directive on Low Voltage • 2014/30/EU Directive on Electromagnetic Compatibility • EN 60974–1 Arc welding equipment - welding current sources • EN 60974–10 Arc welding equipment - EMC requirements • DVS Information Sheet 0901 Arc stud welding of metallic materials •... - Page 54 Heinz Soyer Bolzenschweißtechnik GmbH www.soyer.de Inninger Straße 14 | 82237 Wörthsee | Tel.: +49 8153 8850 | Fax: +49 8153 8030 | E-mail: info@soyer.de |...
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