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Soyer BMK-16 W Operating Instructions Manual

Stud welder
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Operating Instructions
BMK-16 W
Stud Welder

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  • Page 1 Operating Instructions BMK-16 W Stud Welder...
  • Page 2 BMK-16 W...
  • Page 3 Stud Welder Serial number* BMK-16 W stud welder_________________________ Please enter the serial number here, so that the data are immediately available if you need service support Type table for BMK-16 W stud welder Order no. Code designation Note P01329 BMK-16 W...
  • Page 4 BMK-16 W...
  • Page 5 BMK-16 W We congratulate you on purchasing the BMK-16 W SOYER stud welder. You have made an excellent choice. Your BMK-16 W SOYER stud welder was especially developed for high-speed fastening of SOYER welding studs in compliance with DIN EN ISO 13 918 on metallic workpieces.
  • Page 6 BMK-16 W...
  • Page 7 BMK-16 W Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 82237 Wörthsee EC Conformity Declaration in compliance with EC Directive on Machinery 89/392/EEC, appendix II A We herewith declare that the machine described in the following and the version available on the market correspond in its design and construction to the fundamental safety and health requirements stipulated by EC Directive on Machinery.
  • Page 8 BMK-16 W...

  • Page 9: Table Of Contents

    Drawn arc welding with ceramic ferrules ..............17 Stud welder set-up ....................... 18 View / Dimensions ....................... 18 Technical data......................19 Circuit diagram of BMK-16 W ..................20 2.5.1 Wiring diagram, primary (power circuit, 400 volt standard) ......... 20 2.5.2 Wiring diagram, secondary (welding circuit) ..............
  • Page 10 Maintenance ...................... 58 Stud welder ........................58 Cleaning........................58 8.2.1 Detergents ........................58 Replacement of components ..................59 Spare parts list for BMK-16 W ................. 60 Spare parts for BMK-16 W................... 60 Troubleshooting ....................61 10.1 Malfunctions......................... 62 Transport and storage..................65 Terms of warranty.....................
  • Page 11 BMK-16 W Appendix A / Adjustment of short-cycle drawn arc welding guns Appendix A...

  • Page 12: General

    BMK-16 W 1 General The following should be principally observed ... With this stud welder you have purchased a product which • is state-of-the-art technology • fully complies with the current safety requirements and • enables successful working. Before installing the stud welder, please observe the following: •...

  • Page 13: Application

    For this purpose, however, special stud holders and ceramic ferrules or gas shrouds are required. With the BMK-16 W SOYER stud welder it is also possible to weld studs of other metallic materials than steel. It is, however, necessary to first carry out experimental welds and to inspect them.

  • Page 14: Chapters Of Operating Instructions

    BMK-16 W 1.5.1 Chapters of operating instructions The operating instructions describe the start-up and operation of the BMK-16 W stud welder under normal conditions. The present operating instructions of the BMK-16 W stud welder comprise the following chapters in detail: •...

  • Page 15: Conduct In The Case Of Malfunctions

    Contacts and service address If you have any questions regarding the operation of the stud welding system, retrofits or if you require service, please contact your responsible service office or the following address: Heinz Soyer Bolzenschweißtechnik GmbH Etterschlag Inninger Straße 14 D-82237 Wörthsee...

  • Page 16: Description Of Stud Welder

    6 mm to prevent pore formation and to optimise the formation of bulges. The standard BMK-16 W stud welder is suitable for operation with shielding gas and ceramic ferrules. A d.c. power supply provides the welding current. The weld duration and welding current can be selected.

  • Page 17: Drawn Arc Welding With Shielding Gas

    Ensure that the surface is electroconductive. Abrase hot galvanized parts. The following welding methods are possible when using the BMK-16 W SOYER short- cycle drawn arc stud welder: • Short-cycle drawn arc stud welding without shielding gas and ceramic ferrules.

  • Page 18: Stud Welder Set-Up

    The PH-2L stud welding gun with control cable and shielding gas equipment is the standard gun to be connected to the BMK-16 W stud welder. Optionally you may also connect the PH-3N, PH-3L and PK-0K stud welding guns. These operating instructions only refer to the BMK-16 W stud welder.

  • Page 19: Technical Data

    Technical data Designation BMK-16 W Welding process Drawn arc stud welding (DS) SOYER threaded studs, DIN EN ISO 13918 from Welding range M3 – M16 RD (MR) or Ø 2 – 13mm Steel, stainless steel and heat-resistant steel (aluminium Material...

  • Page 20: Circuit Diagram Of Bmk-16 W

    BMK-16 W Circuit diagram of BMK-16 W 2.5.1 Wiring diagram, primary (power circuit, 400 volt standard) Y 400vac white/blue welding transfo (primary) main switch star point mains supply CA20X black (230vac) 400vac blue 50/60Hz 32AT brown (3.15AT) 30°v yellow/green 230vac...

  • Page 21: Wiring Diagram Of Modules

    BMK-16 W 2.5.3 Wiring diagram of modules connection from control transfo °C SO555 controller board (front panel) J1 J3 J5 J4 jumper J1, J 3 open jumper J5, J4 plugged SO565 connection from shunt SO560/16 controller board SO1200 machine PC board...

  • Page 22: Bmk-16 W Interfaces

    BMK-16 W BMK-16 W interfaces 2.6.1 CNC interfaces CNC-interface Customer control 9-pole socket Start External release Start +U external +U external Terminology: Stud on workpiece Is only required when stud welder is operated via an external control. Start Contact releases the welding process.

  • Page 23: Safety Instructions

    BMK-16 W 3 Safety instructions These operating instructions contain basic instructions which have to be complied with during installation and/or operation. It is therefore absolutely necessary that these operating instructions are read by the operator and responsible specialist staff prior to assembly and start-up.

  • Page 24: Staff Qualification And Training

    BMK-16 W Staff qualification and training The staff responsible for operation, maintenance, inspection and assembly must have the respective qualification for carrying out these works. Field of responsibility, competence and the supervision of staff has to be exactly regulated by the user. If your personnel do not have the necessary knowledge, they have to be trained and instructed.

  • Page 25: Before Starting To Weld

    BMK-16 W DANGER When welding, do not wear clothes soiled with easily combustible substances such as oil, grease and paraffin oil etc. • Wear gauntlet gloves made of leather. • Wear neither rings, watches nor electrically conductive jewellery. • Wear protective goggles with eye-protecting lens number 2 (DIN 58211, part 6) to protect your eyes from welding spatters and flashes of light that are generated during the welding process.

  • Page 26: Safety Instructions For Maintenance, Inspection And Assembly

    • Roll up the cables without buckling them. Our GW-1 SOYER tool and gear wagon (optional equipment) is the optimum solution for properly storing SOYER stud welders as well as welding guns, cables, studs, retrofit kits etc.

  • Page 27: The "S" Symbol

    BMK-16 W burn-off, mechanical wear etc. and have damaged parts replaced by the SOYER customer service. 3.14 The “S” symbol MORTAL DANGER The “S” symbol is the symbol for welding current sources permitted for operation with increased electrical danger. The “S” symbol on our stud welders refers exclusively to...

  • Page 28: Installation Of Stud Welder

    BMK-16 W 4 Installation of stud welder The upper side of the BMK-16 W stud welder is equipped with two plastic handles. The handles are intended for transport by hand only. Never pull ropes through these handles to lift the stud welder by means of a crane to the installation site. The welding unit would become instable and might tilt from its original position.
  • Page 29 • Ensure sufficient ventilation of the working room when operating the welding system. NOTE The housing of BMK-16 W stud welder corresponds to safety class IP 21. Please observe that this system of protection is not suitable for being operated or transported...

  • Page 30: Start-Up

    BMK-16 W 5 Start-up Front and rear view Front view of BMK-16 W 1 Fuse element F1 8 Air function "backward" (option) 2 Main switch 9 Control cable connection 3 Fuse element F2 10 Welding cable socket 4 LCD display...

  • Page 31: Operating Elements

    CNC interface or SPS control system 9-pin connector, interface RS 232 (no function) Danger sign Type plate Shielding gas connector Compressed-air supply connection for feeder control (BMK-16 W automatic) Connecting sockets for compressed-air control of feeder (BMK-16 W automatic) 5.1.1 Operating elements •...

  • Page 32: Display Elements

    BMK-16 W • Function keys for setting the welding parameters (item 6, chapter 5.1) The BMK-16 W stud welder has four function keys on the front panel for setting the welding parameters: Function key “arrow up” Function key “arrow down”...

  • Page 33: Led Display

    BMK-16 W When switching the equipment on, the 8 LEDs light up for a short period to check proper operation. If not all LEDs light up when starting the system, please contact your service partner. 5.1.3 • LED display The first line of the display shows the designation of the parameters to be set. The second line shows the set value.

  • Page 34: Connecting Elements

    BMK-16 W 5.1.4 Connecting elements • Mains cable (item 13, chapter 5.1) The mains cable is a four-core (3P + PE), highly flexible connecting cable for connecting the stud welder to the mains supply with a 32 A-CEE-plug • Earth cable connectors (item 12, chapter 5.1) The earth cable connectors serve to connect the earth clamps to the stud welder •...

  • Page 35: Symbols

    BMK-16 W 5.1.5 Symbols Symbol Designation Function Electrical energy Main switch for switching stud welder on and off. LED lights up when earth terminal of stud welder LED "Stud is connected and stud touches the workpiece. on Workpiece" LED lights up when pressing release switch of LED “Release"...

  • Page 36: Fuses (Items 1 And 3, Chapter 5.1)

    BMK-16 W 5.1.6 Fuses (items 1 and 3, chapter 5.1) The BMK-16 W stud welder is protected by the following fuses: - Fuse F1 0.315 A slow - Fuse F2 2 A slow (with 400V up to 500V) or 3.15 AT with 230V...
  • Page 37 BMK-16 W You may determine the symmetry and quality of the arc during the preweld current test and then optimise them by means of adequate combinations of the earth connection and the gun position. Please ensure that the contact areas of the earth clamps are always kept clean and do not oxidize, otherwise high transition resistances could occur that may result in a considerable reduction of the rated welding current.

  • Page 38: Connection Of Stud Welding Gun

    BMK-16 W 5.2.2 Connection of stud welding gun • Connect welding cable of welding gun to the relevant socket (item 10, chapter 5.1) and lock it by turning to the right until stop. • Insert control cable into control cable connection (item 9, chapter 5.1) and tighten with sleeve nut.

  • Page 39: Adjustment Of Operating Modes

    BMK-16 W Adjustment of operating modes 5.3.1 Starting the stud welder After switching the stud welder on, the 8 LED lamps (items 5.1 - 5.8, chapter 5.1.2) light up for a short period. The stud welder carries out a self test (self check) which is shown on the LED display (item 4, chapter 5.1).
  • Page 40 BMK-16 W 5.3.2.2 Operating mode "PRE" (pre-current test) The adjustment "PRE" (pre-current test) enables carrying out welds by means of the set parameters without application of main current and serves to control the gun or head adjustment and to test performance. During this operating mode, an arc is...
  • Page 41 BMK-16 W • Check the immersion depth of the stud and/or set it according to the operating instructions of the welding gun or welding head. CAUTION Ensure once again that operating mode is set to "LIFT" and observe the safety instructions in chapter 3.
  • Page 42 BMK-16 W 5.3.2.4 Operating mode "GAS" (gas test) This operating mode checks whether the shielding gas flows through the gas shroud of the welding gun or welding head. As long as a triggering signal is there, shielding gas flows out of the gas shroud on the welding gun or welding head. This enables you to rinse the gas lines with shielding gas before starting to weld.

  • Page 43: Special Functions

    BMK-16 W Special functions With the stud welder BMK-16 W you can call additional special functions: Start dealing with the special functions when you are familiar with the basic functions of the stud welder. The stud welder must be switched off when calling special functions. In order to call the respective special functions you have to press certain function key combinations and keep them pressed when starting the stud welder.

  • Page 44: Special Function "Setting The Type Of Feeder And Its Functions

    BMK-16 W • The operating counter can be reset to "0" by pressing the function key "arrow right". 5.4.3 Special function "Setting the type of feeder and its functions". With automatic operation, this special function serves to adapt the control to the feeder (parameter 1-4, only with BMK feeder).

  • Page 45: Special Function "Selection Of Language. Display Of Software Version Number

    BMK-16 W Explanation of parameters • Plunger This parameter adjusts the after-blowing time of the stud feed blast air beyond the standard measure when the injection piston in the welding gun/welding head has moved forward to press the stud out of the stud holder. A longer time setting is required when welding e.g.

  • Page 46: Special Function "Setting The Feeder Operation

    BMK-16 W 5.4.5 Special function "Setting the feeder operation" This special function serves as a help for setting the feeder operation when the stud welder is equipped with an optional automatic set. For calling this special function, please proceed as follows: •...

  • Page 47: Operation

    BMK-16 W 6 Operation Standard operation The measures mentioned in the "Start-up of stud welder" chapter have already been performed. 6.1.1 Setting welding parameters for standard welding operation NOTE The applicable accident prevention and safety regulations in chapter 3 have to be complied with when operating the stud welder.
  • Page 48 BMK-16 W The main current times for the most important stud dimensions are represented in tabular form in chapter 6.1.2 "Welding parameters for welding operation“ 6.1.1.3 PCT (pre-current time in milliseconds) • Select function "PCT" by pressing either function key "arrow left" (3) or "arrow right"...
  • Page 49 BMK-16 W 6.1.1.5 RLT (reload time in milliseconds) 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 higher you have to set the reload time correspondingly. If automatic reload is not required, set value "0".

  • Page 50: Welding Parameters For Welding Operation

    The welding parameters were determined with the BMK-16 W stud welder and the PH-3N stud welding gun having a lift setting of about 2.5 mm. A steel plate with a thickness of 5 mm was used as base material for welding SOYER welding studs as per DIN EN ISO 13 918.

  • Page 51: Welding Operation With Shielding Gas

    BMK-16 W Welding operation with shielding gas The measures mentioned in the "Start-up of stud welder" chapter have already been performed. The applicable accident prevention and safety regulations indicated in chapter 3 must be complied with when operating the stud welder.

  • Page 52: Instructions For Welding With Shielding Gas

    BMK-16 W 6.2.2 Instructions for welding with shielding gas • Set the parameters required for your welding task according to the list in chapter 6.1.2. 1 Foot plate 2 Gas shroud 3 Welding stud Ill. Stud welding with shielding gas Set gas flow rate to a value between 4 and 5 L/min.

  • Page 53: Instructions For Welding With Ceramic Ferrules

    BMK-16 W Welding operation with ceramic ferrules is only possible when using SOYER drawn arc welding studs, types PD, MD, RD, UD and SD, similar to DIN EN ISO 13 918. 6.3.1 Instructions for welding with ceramic ferrules • Start the stud welder as described in chapter 5.

  • Page 54: Quality Control

    7 Quality control General Provided that the SOYER stud welding system is properly 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. The following tests are carried out in general practice: •Visual inspection...

  • Page 55: Test Execution

    BMK-16 W Test execution 7.3.1 Production of samples The dimensions of the test piece shall 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 56: Bend Test

    BMK-16 W 7.3.3 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 is welded and bent to an angle of 30° by means of a tube that is slipped over the stud.

  • Page 57: Tensile Test

    Note Numerous special accessories are available for perfectly testing stud welded joints. BP-1 SOYER Bend Testing Device for non-destructive stud testing to support quality assurance procedures DMS-1 SOYER Torque Wrench for non-destructive stud testing to support quality assurance procedures ZPV-1 SOYER Tensile Testing Device for non-destructive stud testing to support quality assurance procedures For further information, please contact our parent company or our customer service responsible for your area or visit our website at www.soyer.de.

  • Page 58: Maintenance

    BMK-16 W 8 Maintenance Stud welder The stud welder is constructed in such a way that only a minimum of maintenance is required. The interior of the stud welder should, however, be cleaned at regular intervals depending on the environmental conditions at the location of use. Any defects of the system’s control unit can be easily eliminated by replacing the printed...

  • Page 59: Replacement Of Components

    BMK-16 W Replacement of components Defective components may only be replaced by trained SOYER servicemen. Perfect function of your stud welder can only be guaranteed when original SOYER spare parts are used. CAUTION Should it become necessary to replace fuses, only use fuses with the prescribed electrical values.

  • Page 60: Spare Parts List For Bmk-16 W

    BMK-16 W 9 Spare parts list for BMK-16 W Spare parts for BMK-16 W In preparation Item No. Quantity Designation Order No.

  • Page 61: Troubleshooting

    The following list of errors, their causes and remedies is designed to help 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 Bolzenschweißtechnik GmbH.

  • Page 62: Malfunctions

    " Connect cable properly or check for damage. Replace if necessary. Connecting plug or socket of stud welder are burnt down. " Have plug or socket replaced by SOYER customer service. Both earth cables are not properly connected or not connected at all, or earth clamps are not attached to the workpiece.
  • Page 63 " Set gas flow rate to 4-5 l/min by means of the control cock. Solenoid valve in stud welder is soiled or defective. " Deaerate solenoid valve, clean it and/or have it replaced by SOYER customer service. Stud does not lift, neither Height of lift is not correctly set.
  • Page 64 BMK-16 W Stud not welded with total Time too short. flange surface, deficient " Readjust time for main current duration according to the list. weld joint strength Poor earth connection " Check earth cables and earth clamps for tight fit, tighten if necessary.

  • Page 65: Transport And Storage

    The stud welder 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-16 W stud welder has two handles on its top for easy transport and mobile use within short distances. CAUTION The handles are intended for transport by hand only.

  • Page 66: List Of Standards And Guidelines

    BMK-16 W 13 List of standards and guidelines • 91/368/EWG EC Directive on Machinery (formerly 89/392 EEC) • 73/23/EEC EC Directive on Low-Voltage 89/336/EEC EC Directive on Electromagnetic Compatibility • DIN EN 292 – 1 Safety of machinery; basic terms, general principles of construction;...

This manual is also suitable for:

P01329P01330

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