Soyer BMK-8i Manuale utente
GB
Operating Manual
Stud welding device
SRM technology
BMK-8i
Stud welding gun PH-9 SRM12
PH-3N SRM
GB
Device numbers
We recommend registering the device numbers here so they can be quickly ac-
cessed if service is needed.
Operating manual
Document no.: P00158, 01-2016, translation of the original manual
(English: P00258)
All information in this document is the property of
Heinz Soyer Bolzenschweißtechnik GmbH.
Device Type Serial number
Stud welding device BMK-8i
Stud welding gun PH-9 SRM12
PH-3N SRM
Revision status
Document Created/modified Editor Date
Original Prepared DD 14.01.2016
Operating Manual Soyer Bolzenschweißtechnik 3
CONTENTS
1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1. Validity of the operating manual 6
1.2. Registered trademarks 6
1.3. Abbreviations and definitions 6
1.4. Declarations of conformity 7
1.5. Manufacturer 9
1.6. Instruction, training 9
1.7. Standards and directives 9
2. Important safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1. Safety alerts used 10
2.2. General safety instructions 11
2.3. Safety instructions for the working method 14
2.4. Personal protection equipment 15
2.5. Intended use of the stud welding device 16
2.5.1 Incorrect use 16
2.6. Intended use of the stud welding guns 16
2.6.1 Incorrect use 16
2.7. Operating company prerequisites 17
2.7.1 Requirements for personnel 17
3. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4. Storage, shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5. Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6. Description of the BMK-8i stud welding device . . . . . . . . . . . . . . . . . . . . . . . 19
6.1. Type designation 19
6.2. Working method 19
6.2.1 Stud welding with SRM technology 20
6.2.2 Drawn arc stud welding technology with shielding gas 20
6.3. Overview of the controls 22
6.3.1 Display and setting area 24
6.4. Technical data of the BMK-8i stud welding device 25
6.5. Permitted stud welding guns 26
4 Operating Manual Soyer Bolzenschweißtechnik
CONTENTS
6.6. Cleaning the stud welding device 27
7. Description of the SRM stud chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1. Setting the SRM stud chuck 28
8. Description of the PH-9 SRM12 stud welding gun . . . . . . . . . . . . . . . . . . . . . 30
8.1. Technical data of the PH-9 SRM12 stud welding gun 31
8.2. Replacing the SRM stud chuck in PH-9 SRM12 32
8.3. Replacing the SRM12 support pipe insert with PH-9 SRM12 34
8.4. Cleaning the stud welding gun 35
9. Description of the PH-3N SRM stud welding gun . . . . . . . . . . . . . . . . . . . . . . 36
9.1. Technical data of PH-3N SRM stud welding gun 37
9.2. Replacing the SRM stud chuck with PH-3N SRM 38
9.3. Cleaning the stud welding gun 40
10. Setup and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10.1. Requirements for the installation location 41
10.2. Connection of the stud welding device and the stud welding guns 42
10.2.1 Mains connection 42
10.2.2 Connecting the earth cable 42
10.2.3 Connecting the stud welding gun 43
10.2.4 Connecting the shielding gas supply 43
11. Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.1. Setting the welding parameters 47
11.1.1 Help tables for device setting 47
11.1.2 Setting the welding current and the welding time 49
11.1.3 Setting/deactivating the SRM current 50
11.1.4 Setting the gas preflow time 51
11.1.5 Setting the lift time (height of lift) in "Setup" mode 52
12. Welding operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
12.1. Carrying out welding 54
12.2. Notes on checking the quality of the weld 56
12.2.1 Visual inspection 56
12.3. Switching off the device 57
12.4. Weld defects and their causes 58
Operating Manual Soyer Bolzenschweißtechnik 5
CONTENTS
13. Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
14. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
15. Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
General information
6 Operating Manual Soyer Bolzenschweißtechnik
1. General information
This operating manual contains important information and requirements for oper-
ating the devices. Keep the operating manual in a readily accessible location
close to the devices.
The term 'devices' in the operating manual refers to the stud welding device and
the stud welding gun.
Carefully read through the operating manual and the other documents contained
in the technical documentation. In particular, comply with the safety instructions
which are intended to help you recognise any residual risks and prevent hazards.
The drawings and diagrams in this operating manual help illustrate the content
and may vary slightly from the actual equipment.
The manufacturer reserves the right to make technical changes.
1.1 Validity of the operating manual
This operating manual applies to the following devices:
1.2 Registered trademarks
The following terms in this manual are marked with registered trademarks:
1.3 Abbreviations and definitions
Essential abbreviations or designations in this manual:
Stud welding device BMK-8i
Stud welding guns PH-9 SRM12
PH-3N SRM
SRM®: SRM stands for magnetic field stud welding and refers to welding
or stud welding in a radially symmetrical magnetic field.
SOYER®: Developments/technologies of Soyer GmbH.
HZ-1 threaded studs: SOYER universal studs with centring tip.
MF threaded studs: SOYER threaded stud with a reduced flange diameter
(MF stands for mini flange).
General information
Operating Manual Soyer Bolzenschweißtechnik 7
1.4 Declarations of conformity
The devices are built according to the generally accepted codes of practice.
i
Please note that significant modifications to the device can void the
declaration of conformity.
In addition, the manufacturer warranty coverage may be rendered inva-
lid.
General information
8 Operating Manual Soyer Bolzenschweißtechnik
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. Any unauthorised modification to this machine automatically annuls this
declaration.
Designation of machine :
Stud welding device
Machine type :
BMK-8i
Machine no. : ______________________
Applicable EU directives : RoHS Directive (2011/65/EU)
Low Voltage Directive (2014/35/EU)
EMC Directive (2014/30/EU)
Applied harmonised : EN 60 974-1:2012
standards, in particular EN 60 974-10:2008
Applied national standards : DGUV Regulation 1
Date : 17 May 2016
Producer’s signature : ____________________
Signer’s function : Managing Director
General information
Operating Manual Soyer Bolzenschweißtechnik 9
1.5 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: [email protected]
Web: www.soyer.de, www.soyer.com
1.6 Instruction, training
Soyer offers optional and individual instruction in the operation of the devices.
Soyer also offers training for customer-specific use of the devices.
Information about the scope and costs of instruction and training can be obtained
from Soyer GmbH.
1.7 Standards and directives
The following standards (among others) must be observed for carrying out stud
welding work and for the qualification of personnel:
• DIN EN ISO 14555 Welding - Arc stud welding of metallic materials
• DIN EN ISO 14732 Welding personnel - Qualification testing of welding oper-
ators and weld setters for mechanized and automatic welding of metallic ma-
terials
• DIN EN 60974-9 Arc welding equipment - Part 9: Installation and use
• DVS data sheet 0904 Practical tips - Arc stud welding
Important safety instructions
10 Operating Manual Soyer Bolzenschweißtechnik
2. Important safety instructions
Read the following chapters carefully and follow the safety instructions. If you are
uncertain or an instruction cannot be followed, please contact the manufacturer.
The devices have been built according to the generally accepted codes of prac-
tice and in compliance with, and application of, the usual and established safety
requirements. To achieve the maximum possible safety, it is essential that all of
the safety instructions in this operating manual are heeded and followed.
2.1 Safety alerts used
Warning signs are used in this document, depending on the potential danger of
the situation.
Safety and information symbols used in this manual
This safety alert indicates an imminently hazardous
situation which will result in serious injury or death.
This safety alert indicates a potentially dangerous
situation which could result in serious physical
injury or death.
This safety alert indicates a potentially hazardous
situation which could result in minor or moderate
injury.
This alert, without the triangle, is also used for
potentially hazardous situations which will result in
property damage.
Additional information indicating danger from elec-
tric current. The additional information is used in
conjunction with a warning sign.
Additional information on the risk of burns. The
additional information is used in conjunction with a
warning sign.
Do not touch the surface of the housing, danger of
electrocution.
Do not touch or open, danger for unauthorised per-
sons.
Danger for persons with a heart pacemaker or
other medical implants.
The info sign is not a safety alert. It indicates impor-
tant and useful information on the subject.
DANGER
!
WARNINGWARNING
!
CAUTIONCAUTION
!
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