Soyer BMK-12 W User manual

Keep this quick start guide in a safe place and ensure that all users are familiar with the
contents.
Stud Welding – Practical Knowledge
Quick Start Guide –
BMK-12W Stud Welder

Stud welding – Practical knowledge: BMK-12W
Page - 2
Introduction
This quick start guide is designed to provide you with all the information you need to start up and
operate your stud welder fast and efficiently.
The operating personnel must be able to consult this guide when necessary. Store this guide in a
place accessible to every operator.
F
FO
OR R Y
YO
OU UR R S
SA
AF FE ET TY Y
This quick user guide should not be regarded as a substitute for the
comprehensive operating instructions delivered with your stud welder.
Read all of these operating instructions prior to start-up. Please follow all safety
precautions as well as all chapters of these operating instructions before
starting to weld. Non-compliance with the safety precautions can result in
serious personal injuries or death.
SOYER®is a registered trade mark of Heinz Soyer Bolzenschweißtechnik GmbH.
It is prohibited to transmit or reprint this document, as well as to utilize or disclose its contents,
unless this has been expressly granted.
Non-compliance with this regulation is liable to compensation. All rights reserved, particularly in
the case of a patent grant or a GM registration.
We have verified that the contents of this pamphlet correspond to the hard- and software
described. Deviations, however, cannot be excluded so that we cannot warrant for absolute
compliance.
The illustrations contained in this instruction manual may vary in some details from your
product. This, however, has no influence on the handling of the machine.
The data in this documentation have been verified regularly and necessary corrections will be
incorporated in future impressions. Any suggestions for improvement will be appreciated.
We hope you enjoy using the BMK-12W SOYER stud welder as much as we enjoyed developing it.
Date of issue: 01.09.2008
Revision:
Print: 03 Sep. 08
© Heinz Soyer Bolzenschweißtechnik GmbH 2008 • All rights reserved
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
82237 Wörthsee-Etterschlag, Germany
Tel.: [phone] - 885 - 0
Fax: [phone] – 8030
www.soyer.de i[email protected]e

Stud welding – Practical knowledge: BMK-12W
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Table of contents
1. Front and rear view of stud welder _________________________________ 4
2. Quick start-up instructions for single components ___________________ 6
2.1. Start-up _________________________________________________________ 6
2.2. Operating modes / Parameters ______________________________________ 9
2.3. Standard stud chucks ____________________________________________ 11
2.4. Basic setting of the stud chuck with adjusting screw __________________ 12
2.5. Start-up of PH-3N welding gun _____________________________________ 13
2.6. Welding operation using ceramic ferrules____________________________ 16
2.7. Start-up of PK-3 welding gun ______________________________________ 19
2.8. Start-up of PK-0K welding gun _____________________________________ 23
3. Welding parameters ____________________________________________ 26
4. Important wear and spare parts __________________________________ 27
4.1. Wear parts list for PH-3N welding gun _________________________________ 27
4.2. Wear parts list for PK-3 welding gun ________________________________ 30
4.3. Wear parts list for PK-0K welding gun _______________________________ 31
5. Helpful standards ______________________________________________ 32
6. Helpful hints __________________________________________________ 33

Stud welding – Practical knowledge: BMK-12W
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1. Front and rear view of stud welder
1 2 3 4 5 6
13 12 11 10 9 8 7
Front view of BMK-8U / BMK-12 W (above illustration of BMK-12W corresponds to BMK-8U)
1 • Fuse element F1
2 • Main switch (to switch stud welder on)
3 • Fuse element F2
4 • LCD display
5 • Indicator lamps for function control
6 • Function keys for setting the welding parameters
7 • Air function "forward" (option)
8 • Air function "backward" (option)
Connection for welding guns or heads with automatic stud feed
9 • Control cable connection
10 • Welding cable socket
The control cable connection and the welding cable socket serve to connect the stud welding
guns or heads to the stud welder.
11 • Gas connection socket
Before welding with shielding gas, connect the gas hose of the welding gun or head to the gas
connection socket.
12 • Earth cable connectors
The earth cable connectors serve to connect the earth clamps to the stud welder.
13 • Mains cable
The mains cable is a four-core (3P + PE), highly flexible connecting cable for connecting the
stud welder to the mains supply.
13a Welding parameter table
Table indicating welding parameters for the welding operation (standard values)

Stud welding – Practical knowledge: BMK-12W
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14 15 16 17 18
20/21 19
Rear view of BMK-8U / BMK-12 W
14 15-pole connecting socket / feeder interface (OPTION)
The feeder interface serves to connect the feeder control to the stud welding device
15 9-pole connecting socket / CNC interface (OPTION)
The CNC interface serves to be connected with an external control system to control the stud welding
process
16 9-pin connector, interface RS 232 (OPTION)
This interface serves to be connected with an external control system
17 Danger sign
18 Type plate
19 Shielding gas connector
This connection serves to supply the stud welder with gas by means of a pressure reducer. The
admissible gas flow value ranges between 4 and 5 l/min
20/21 Compressed-air supply connection (OPTION)
This connection serves to supply the stud welder with compressed air and to connect the compressed
air lines of the feeder control to the stud welder. The admissible supply pressure amounts to a
maximum of 7bar

Stud welding – Practical knowledge: BMK-12W
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2. Quick start-up instructions for single components
2.1. Start-up
All operating and safety instructions must be read carefully and must be fully understood
before using the BMK-12W stud welder!
DANGERS:
•Persons with pacemakers must neither operate the stud welding equipment nor stay near it
while it is running.
•Never touch weld stud or stud chuck during the welding process. These components are
current-carrying!
•The applicable accident prevention and safety regulations have to be complied with when
operating the stud welder.
•Please also observe the safety instructions of the Employer’s Liability Insurance Associations.
How to install the stud welder:
Connect both earth cables and lock them by turning to the right
till stop.
Ensure a tight fit of connection cables!
Please note:
The GW-1 or GW-2 SOYER tool and gear wagon is the
optimum solution for the proper installation of the stud welder
(accessories – must be ordered separately).
If required,connect gas supply.
When using stud diameters exceeding 6 mm, we recommend
the application of shielding gas in order to prevent pore
formation and to optimise bulging.
Set gas flow rate to a value between 3 and 5 l/min.
Gas mixture containing
80% of Argon and 20% of CO2
82% of Argon and 18% of CO2
85% of Argon and 15% of CO2
Connect welding cable of welding gun to the welding cable
socket and lock it by turning to the right until stop.
Insert control cable into control cable connection and lock it by
turning to the right until stop.

Stud welding – Practical knowledge: BMK-12W
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If required, prepare ground connection (please use protective
goggles).
Earth connection points at the workpiece must be blank. If
necessary, grind the surface of contact areas to clean bright
metal.
Ideal condition: The stud is located in
the centre of both earth connections.
Attach the earth clamps to the workpiece. Always attach both
earth clamps (arc blow!).
Only attach both earth cables to the workpiece being welded in
order to prevent high transition resistances.
If required, prepare welding points at the workpiece (pls. use
protective goggles).
If necessary, grind the area to be welded to clean bright metal.
Connect mains cable to power supply.
Ensure correct connected loads for electrical
connections (please refer to the stud welder’s
type plate)
Standard connection
CEE 32 A (3P + protective earth conductor)
3 x 400 V 50/60 Hz
Special connection of
3 x 230, 3 x 440 or 3 x 500 V 50/60 Hz possible

Stud welding – Practical knowledge: BMK-12W
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Switch stud welder on by means of the mains switch. The stud
welder carries out a self test.
Please observe the safety instructions.
Select parameters in accordance with your welding task.

Stud welding – Practical knowledge: BMK-12W
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2.2. Operating modes / Parameters
Press the function key "arrow right" or "arrow left" (3 or 4) to select the parameters. Only the
parameter designation which is flashing on the display can be set by means of the function keys (1 or
2).
.
Overview – Operating modes / Parameters
MODE MCTIME PCTIME GPTIME RLTIME
OP 1 40 0 0
PRE 2 60 100 100
LIFT UP TO UP TO UP TO UP TO
GAS 1000 1000 9900 9900
Explanation of operating modes:
OP Operating state
The operating mode "OP" allows normal welding operation with the welding parameters set.
PRE Preweld current test
The adjustment "PRE" enables you to test performance using the set parameters without application
of main current and serves to control the adjustment of the welding gun.
LIFT Lift test
This operating mode enables you to adjust or check the lift of the welding gun.
GAS Gas test
This operating mode checks whether shielding gas flows through the gas shroud of the welding gun.
As long as the push button is pressed, shielding gas flows out of the gas shroud on the welding gun.

Stud welding – Practical knowledge: BMK-12W
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Explanations of parameters:
• MCTIME Main current time
MCTIME is the most important parameter for the welding operation.
• You can change the value for the main current time from 1 - 1000 ms in 1 ms-steps by pressing
either function key "arrow up" or "arrow down".
Please note:
The parameters for the most important stud diameters are represented in tubular form on the
stud welder’s front panel.
• PCTIME Pre-current time
• It is possible to change the value for the pre-current time by pressing either function key "arrow up”
or "arrow down". The period of time can be set between 40 and 1000 ms in 20 ms-steps.
Please note:
A period of time set between 40 and 80ms suffices in most cases (please refer to adjustment
table).
• GPTIME Gas pre-flow time
The gas pre-flow time is the period of time, during which the shielding gas valve is open before
starting the welding process and remains open after the welding process has been completed. Select
the corresponding value for the gas pre-flow time from 100 - 9900 ms in 100 ms-steps by pressing
function key "arrow up" or "arrow down" (please refer to adjustment table).
Please note:
Set "0" when welding without shielding gas.
• RLTIME Reload time (OPTION)
The reload time can only be used in conjunction with optional "automatic operation" (feeder
connection).
Please note:
Set "0" when using the PH-3N, PK-3 and PK-0K welding guns.

Stud welding – Practical knowledge: BMK-12W
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2.3. Standard stud chucks
Please note: Standard drawn arc chucks are available in the following different sizes: M6, M8, M10
and M12. When using smaller studs, please use a special stud chuck with setscrew.
•The stud chuck is screwed on an adapter piece and
can be installed into the PH-3 and PK-3 stud welding
guns.
•For different stud diameters, different stud chucks are
required.
•Drawn arc stud chucks are especially suitable for
operation with ceramic ferrules.
Check to see if the stud chuck is tightly screwed after installing
it, otherwise there is a risk of scorching during the welding
process.
Insert weld stud into stud chuck.
Specific feature: Depending on the length of the weld stud
being welded, stud protrusion may exceed 3 mm.

Stud welding – Practical knowledge: BMK-12W
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2.4. Basic setting of the stud chuck with adjusting screw
•The standard stud chuck is suitable for being installed
in the PH-3N, PK-3 and PK-0K welding guns.
•For different stud diameters, different stud chucks are
required.
•For the PH-3N and PK-3 welding guns, use a stud
chuck with adjusting screw, having a length of 73
mm!
•For PK-0K welding gun, use a stud chuck with
adjusting screw, having a length of 45 mm!
Insert weld stud into stud chuck.
The weld stud must make contact with the stop screw. Adjust
stop screw in the stud chuck by turning it until the distance
between the top edge of the stud flange and the front edge of
the stud chuck equals 1.5 mm – 3 mm.
Secure stop screw (4) by means of counternut (3).
Ensure depth of immersion / stud protrusion is set between 1.5
mm and 3 mm.
After adjustment, check and correct if necessary. Hand-tighten
by means of the fixing nut.

Stud welding – Practical knowledge: BMK-12W
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2.5. Start-up of PH-3N welding gun
Please note: The PH-3N welding gun is only suitable for stud sizes M3 - RD12!
Tip:
The PH-3N welding gun is provided with a standard gas shroud. We recommend the application of
shielding gas to prevent pore formation and to optimise the formation of bulges.
Please note:
To facilitate the installation of the stud chuck, move the
support tube.
For doing so, loosen the four Allen screws.
The stud welder must be switched off when
installing the stud chuck.
Loosen sleeve nuts by means of SW 17 socket
wrench or SW 17 open-end wrench.
Insert the chuck into the spring piston and push it firmly until it
comes to a stop.
Hand-tighten sleeve nut by means of SW 17 socket wrench or
SW 17 open-end wrench.

Stud welding – Practical knowledge: BMK-12W
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How to correct the stud protrusion
Insert the stud into the chuck and push it firmly until it comes
to a stop.
Use Allen wrench (size 3) to loosen the four Allen screws.
Move support until the required stud protrusion of about
1,5 – 3mm mm is obtained.
Tighten Allen screws.
Ensure stud protrusion is set between 1.5 mm – 3 mm
The stud must protrude for about 1.5 - 3 mm from the gas shroud!
Switch stud welder on by means of the mains switch.
Please observe the safety instructions.
Adjusting and checking the height of lift
The height of lift is the distance for which the stud is lifted from
the workpiece during the welding process. This distance is
required for igniting the arc.
The height of lift should amount to approx. 2 mm.

Stud welding – Practical knowledge: BMK-12W
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To adjust and check the height of lift, please select the
operating mode “Lift Test”.
• Position welding gun on the workpiece
• Press push button. The gun lifts the chuck with weld stud
away from the workpiece.
Adjustment of the gun lift is achieved by turning the rear
adjustment cap of the welding gun to the left or to the right.
Anti-clockwise rotation increases the gun lift and conversely
clockwise rotation reduces the gun lift.
Please ensure that the welding parameters are set in
accordance with the respective stud diameter.
If required, check and adjust welding parameters accordingly.
Position welding gun vertically on the workpiece (at a 90-
degree angle to the workpiece).
Check once again the selected parameters. Release welding
process by pressing the push button.
During the welding process, keep gun steady. After having
completed the welding process, remove gun vertically from
the welded stud to prevent widening and damaging of the stud
chuck.
Please observe carefully all safety instructions!
Welding process

Stud welding – Practical knowledge: BMK-12W
Page - 16
2.6. Welding operation using ceramic ferrules
The PH-3N welding gun can also be provided with a ceramic ferrule chuck.
The procedural method is same for both welding with shielding gas and ceramic ferrules. For ceramic
ferrule welding, however, equip the welding gun with a ceramic ferrule before starting to weld.
• Only use ceramic ferrules which are absolutely dry and do not show any flaws.
• Only use ceramic ferrules which match the type and size of the studs.
quip the welding gun with the appropriate stud chuck and
ceramic ferrule chuck.
Make sure stud is centred in the ceramic ferrule chuck to
prevent the stud getting jammed during the lifting process.
How to correct the stud protrusion
Insert the stud into the chuck and push it firmly until it comes
to a stop. Place ceramic ferrule on ceramic ferrule chuck.
Use Allen wrench (size 3) to loosen the four Allen screws.
Move support until the relevant stud protrusion of about 2 mm
is obtained.
Tighten Allen screws again.

Stud welding – Practical knowledge: BMK-12W
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Ensure stud protrusion is set between 1.5 mm – 3 mm
The stud must protrude for about 1.5 - 3 mm from the ceramic ferrule!
Switch stud welder on by means of the mains switch.
Please observe the safety instructions.
Adjusting and checking the height of lift
The height of lift is the distance for which the stud is lifted from
the workpiece during the welding process. This distance is
required for igniting the arc.
The height of lift should amount to approx. 2 mm.
To adjust and check the height of lift, please select the
operating mode “Lift Test”.
• Position welding gun on the workpiece
• Press push button. The gun lifts the chuck with weld stud
away from the workpiece.
Adjustment of the gun lift is achieved by turning the rear
adjustment cap of the welding gun to the left or to the right.
Anti-clockwise rotation increases the gun lift and conversely
clockwise rotation reduces the gun lift.

Stud welding – Practical knowledge: BMK-12W
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Please ensure that the welding parameters are set in
accordance with the respective stud diameter.
If required, check and adjust welding parameters accordingly.
Position welding gun vertically on the workpiece (at a 90-
degree angle to the workpiece).
Check once again the selected parameters. Release welding
process by pressing the push button.
During the welding process, keep gun steady. After having
completed the welding process, remove gun vertically from
the welded stud to prevent widening and damaging of the stud
chuck.
Please observe carefully all safety instructions!
Welding process
Tip:
After completion of the welding process, the welding gun or
welding head should be held in position for about 5 seconds to
allow solidification of the molten metal.
Knock off ceramic ferrule from the welded area.

Stud welding – Practical knowledge: BMK-12W
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2.7. Start-up of PK-3 welding gun
Please note: The PK-3 welding gun is suitable for stud sizes M3 - M10!
The illustrations below show how to install the stud chuck.
Ensure depth of immersion / stud protrusion is set between 1.5
mm and 3 mm.
After adjustment, check and correct if necessary. Hand-tighten
by means of the fixing nut.
Please note:
To facilitate the installation of the stud chuck, move the
support tube.
For doing so, loosen the four Allen screws.
The stud welder must be switched off when
installing the stud chuck.
Loosen sleeve nuts by means of SW 17 socket
wrench or SW 17 open-end wrench
Insert the chuck into the spring piston and push it firmly until it
comes to a stop.
Hand-tighten sleeve nut by means of SW 17 socket wrench or
SW 17 open-end wrench.

Stud welding – Practical knowledge: BMK-12W
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How to correct the stud protrusion
Insert the stud into the chuck and push it firmly until it comes to
a stop. Use Allen wrench (size 3) to loosen the four Allen
screws.
Move support until the required stud protrusion of about 2 mm
is obtained.
Tighten Allen screws again.
Ensure stud protrusion is set between 1.5 mm – 3 mm
The stud must protrude for about 1.5 - 3 mm from the gas shroud!
Switch stud welder on by means of the mains switch.
Please observe the safety instructions.