Soyer BMK-16 W User manual

Operating Instructions
BMK-16 W
Stud Welder

BMK-16 W
2

BMK-16 W
Operating Instructions
BMK-16 W
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 Standard device (3 x 400 volt power supply)
P01330 BMK-16 W automatic Standard device (3 x 400 volt power supply)
and automatic set for stud reload
Heinz Soyer Bolzenschweißtechnik GmbH
Etterschlag
Inninger Straße 14
82237 Wörthsee
Telephone [phone] - 885 - 0
Telefax +49 (0) 8153 – 8030
www.soyer.de
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BMK-16 W
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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.
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.
Some details of the illustrations shown in these operating instructions may be different
from your product. This, however, does not have any influence on the operation.
The data in this documentation, however, have been verified regularly and necessary
corrections will be incorporated in future impressions. We appreciate any suggestions
for improvement.
Date of issue: August 01, 2002
© Heinz Soyer Bolzenschweißtechnik GmbH 2002 · All rights reserved
Printed in the Federal Republic of Germany
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BMK-16 W
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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. Any modification of this machine
without confirmation shall automatically annul this declaration.
Designation of machine : Stud Welder
Machine type : BMK-16 W
Machine no. : ___________________________________
Applicable EC directives : EC Directive on Machinery (89/392/EEC) in the version
91/368/EEC
EC Directive on Low Voltage (73/23/EEC)
EC Directive on Electromagnetic Compatibility
(89/336/EEC)
Applied harmonised EN 292 - 1 and EN 292 - 2, EN 60 204 - 1
standards, in particular : EN 60 974 - 1
Applied national standards VBG 1, VBG 4, VBG 5,
and technical specifications,
in particular : VDE 0544
Date : June 01, 2002
Producer’s signature : ___________________________________
Signer’s function : Technical Management
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BMK-16 W
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BMK-16 W
Table of contents
1General............................................................................................................... 12
1.1 The following should be principally observed ............................................................. 12
1.2 Application ................................................................................................................... 13
1.3 Information on the product........................................................................................... 13
1.4 Type plate .................................................................................................................... 13
1.5 Information on the documentation............................................................................... 13
1.5.1 Chapters of operating instructions ............................................................................... 14
1.5.2 Information on operating instructions........................................................................... 14
1.5.3 Conduct in the case of malfunctions............................................................................ 15
1.6 Contacts and service address ..................................................................................... 15
2Description of stud welder............................................................................... 16
2.1 Short-cycle drawn arc technology................................................................................ 16
2.1.1 Drawn arc welding with shielding gas.......................................................................... 17
2.1.2 Drawn arc welding with ceramic ferrules ..................................................................... 17
2.2 Stud welder set-up....................................................................................................... 18
2.3 View / Dimensions ....................................................................................................... 18
2.4 Technical data.............................................................................................................. 19
2.5 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)................................................................ 20
2.5.3 Wiring diagram of modules .......................................................................................... 21
2.6 BMK-16 W interfaces................................................................................................... 22
2.6.1 CNC interfaces............................................................................................................. 22
3Safety instructions ........................................................................................... 23
3.1 Description of reference signs in the operating instructions........................................ 23
3.2 Staff qualification and training...................................................................................... 24
3.3 Dangers in the case of non-compliance with safety instructions................................. 24
3.4 Safety-conscious working............................................................................................ 24
3.5 Safety instructions for the operator/user...................................................................... 24
3.6 The following should be observed before starting the system…................................. 24
3.7 Before starting to weld ................................................................................................ 25
3.8 Safety precautions at installation site .......................................................................... 25
3.9 Working with the stud welding equipment ................................................................... 25
3.10 Safety instructions for maintenance, inspection and assembly................................... 26
3.11 Unauthorized retrofit and spare parts production........................................................ 26
3.12 Inadmissible operating methods.................................................................................. 26
3.13 Stopping the stud welder ............................................................................................. 26
3.14 The “S” symbol............................................................................................................. 27
4Installation of stud welder ............................................................................... 28
5Start-up.............................................................................................................. 30
5.1 Front and rear view...................................................................................................... 30
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BMK-16 W
5.1.1 Operating elements...................................................................................................... 31
5.1.2 Display elements.......................................................................................................... 32
5.1.3 • LED display................................................................................................................ 33
5.1.4 Connecting elements ................................................................................................... 34
5.1.5 Symbols ....................................................................................................................... 35
5.1.6 Fuses (items 1 and 3, chapter 5.1) .............................................................................. 36
5.2 Preparation for start-up................................................................................................ 36
5.2.1 Earth connection .......................................................................................................... 36
5.2.2 Connection of stud welding gun................................................................................... 38
5.2.3 Gas supply ................................................................................................................... 38
5.2.4 Power supply ............................................................................................................... 38
5.3 Adjustment of operating modes................................................................................... 39
5.3.1 Starting the stud welder ............................................................................................... 39
5.3.2 Operating modes / parameters .................................................................................... 39
5.4 Special functions.......................................................................................................... 43
5.4.1 Special function "Erasing the working storage" ........................................................... 43
5.4.2 Special function " Display of operating counter".......................................................... 43
5.4.3 Special function "Setting the type of feeder and its functions". ................................... 44
5.4.4 Special function "Selection of language. Display of software version number"........... 45
5.4.5 Special function "Setting the feeder operation" ........................................................... 46
6Operation........................................................................................................... 47
6.1 Standard operation ...................................................................................................... 47
6.1.1 Setting welding parameters for standard welding operation........................................ 47
6.1.2 Welding parameters for welding operation .................................................................. 50
6.1.3 Minimum sheet thickness when welding with drawn arc operation ............................. 50
6.2 Welding operation with shielding gas .......................................................................... 51
6.2.1 Preparation of gas supply ............................................................................................ 51
6.2.2 Instructions for welding with shielding gas .................................................................. 52
6.3 Welding operation with ceramic ferrules...................................................................... 52
6.3.1 Instructions for welding with ceramic ferrules.............................................................. 53
6.4 Stopping the stud welder ............................................................................................. 53
7Quality control .................................................................................................. 54
7.1 General........................................................................................................................54
7.2 Demands on the company........................................................................................... 54
7.3 Test execution.............................................................................................................. 55
7.3.1 Production of samples ................................................................................................. 55
7.3.2 Visual inspection .......................................................................................................... 55
7.3.3 Bend test...................................................................................................................... 56
7.3.4 Tensile test................................................................................................................... 57
8Maintenance...................................................................................................... 58
8.1 Stud welder.................................................................................................................. 58
8.2 Cleaning.......................................................................................................................58
8.2.1 Detergents ................................................................................................................... 58
8.3 Replacement of components....................................................................................... 59
9Spare parts list for BMK-16 W......................................................................... 60
9.1 Spare parts for BMK-16 W........................................................................................... 60
10 Troubleshooting ............................................................................................... 61
10.1 Malfunctions................................................................................................................. 62
11 Transport and storage...................................................................................... 65
12 Terms of warranty............................................................................................. 65
13 List of standards and guidelines .................................................................... 66
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BMK-16 W
Appendix A /
Adjustment of short-cycle drawn arc welding guns Appendix A
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BMK-16 W
1 General
1.1 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:
• Store the operating instructions in a place accessible to every operator
• Ensure that the respective operator has read and understood the operating
instructions prior to installation. Each operator should confirm this per
signature.
• Prevent the stud welder being operated by unauthorized personnel
• Only trained personnel may operate the stud welder
DANGER
Persons with pacemakers must not operate the stud welding equipment and
must not stay near it while it is running. Ensure that the stud welding
equipment is not operated near electronically sensitive life-supporting
equipment, such as in intensive care units in hospitals.
CAUTION
Keep sufficient distance from electronic devices. When stud welding, highly
intensive electromagnetic fields are created which may permanently damage
these devices (e.g. television sets).
• Moreover, please observe the safety instructions in chapter 3.
• Call a doctor in case of an accident.
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BMK-16 W
1.2 Application
The BMK-16 W SOYER stud welder for short-cycle drawn arc welding allows SOYER
threaded studs as per DIN EN ISO 13918 and ranging from M3 – M16 RD (MR) or Ø 2
– 13mm (studs, shear connectors, concrete anchors) made of plain, stainless and
heat-resistant steel to be welded on different workpieces (sheets, tubes, steel girders
etc.).
Usually round pins with or without thread are welded. You may also weld fasteners
with different cross-sectional shapes. 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.
If you need consultation or assistance in solving problems, please contact either our
parent company or our field engineers.
1.3 Information on the product
Manufacturer Heinz Soyer Bolzenschweißtechnik GmbH
Etterschlag
Inninger Straße 14
D-82237 Wörthsee
Telephone [phone]
Telefax [phone]
www.soyer.de
Product designation BMK-16 W Stud Welder
Country of origin Germany
1.4 Type plate
The type plate is located on the rear side of the stud welder. It contains the following
information:
• Manufacturer’s name
• Address of manufacturer or agency
• Country of origin
• Product designation
• Mains connection values
• Performance data
• Production number / year of construction
1.5 Information on the documentation
The following operating instructions are supplied with the BMK-16 W stud welder:
• Operating instructions for BMK-16 W stud welder
Order no.: P00227
For repeat-orders please contact your responsible service office or our parent
company. Please refer to chapter 1.6.
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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:
• Chapter 1 General
• Chapter 2 Description of stud welder
• Chapter 3 Safety instructions
• Chapter 4 Installation of stud welder
• Chapter 5 Start-up
• Chapter 6 Operation
• Chapter 7 Quality control
• Chapter 8 Maintenance
• Chapter 9 Spare parts list for BMK-16 W
• Chapter 10 Troubleshooting
• Chapter 11 storageTransport and
• Chapter 12 Terms of warranty
• Chapter 13 List of standards and guidelines
1.5.2 Information on operating instructions
Legal relationship
We draw your attention to the fact that the contents of these operating instructions are
neither part of any former or existing arrangement, pledge or legal relationship nor are
designed for modifying the latter. All obligations of Heinz Soyer Bolzenschweißtechnik
GmbH result from the respective contract of purchase which also comprises the
complete and generally valid warranties. These contractual warranty terms are neither
extended nor restricted by the implementation of these operating instructions.
CAUTION
Do not carry out any actions on the stud welder without specifically knowing the
operating instructions or the respective part. Ensure that only qualified personnel
familiar with the operating instructions and the necessary technical activities (training!)
operate the system.
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BMK-16 W
1.5.3 Conduct in the case of malfunctions
If malfunctions occur, first try to detect and eliminate the causes according to the list in
chapter 10 "Troubleshooting" of the operating instructions. In all other cases, please
contact our service department.
If you require our service, please make sure that you supply us with the following
information:
• Customer number
• Product designation
• Serial number
• Year of construction
• Options
• Material of stud and workpiece
• Stud dimensions
This information will help us both to save time and unnecessary costs, e.g. caused by
delivering the wrong spare parts.
1.6 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
Telephone [phone]
Telefax [phone]
[email protected]
www.soyer.de
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BMK-16 W
2 Description of stud welder
2.1 Short-cycle drawn arc technology
Illustration 1:Short-cycle drawn arc technology
The BMK-16 W SOYER stud welder runs according to the principle of short-cycle
drawn arc stud welding. For detailed information, please refer to the following
regulations:
• DIN EN ISO 14555, "Arc welding of metallic materials“
• DVS Information Sheet 0902, "Drawn arc welding“
When welding, the stud is positioned on the workpiece. The preweld current is ignited
and the stud is lifted off the workpiece. The subsequent ignition of the main current
creates a molten pool between stud and workpiece. The stud immerses in the liquid
molten pool and the material solidifies.
This method allows manual, semi-automatic and fully automatic inseparable welding
of threaded stud fasteners, pins, balls, T-bolts, tapped studs, insulating pins, special
studs and many other fasteners made of steel, CrNi steel, heat-and acid-resisting
steel with the workpieces. Conditionally it is also possible to weld nickel and titanium
depending on the respective requirements. Standard studs for drawn arc and
capacitor discharge welding in compliance with DIN EN ISO 13918 can be welded
without requiring any auxiliary aids. The application of shielding gas or ceramic
ferrules is recommended for studs with a diameter of more than 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. Owing to the low penetration depth of about 0.4
mm, the short-cycle drawn arc method can be applied from a sheet thickness of 0.6
mm on. It guarantees particularly safe, uniform and reproducible stud welded joints
without high requirements to setting accuracy and stud tip quality. Application is
especially recommended for workpieces with difficult surface characteristics, e.g. oil,
grease, zinc and other galvanic treatments as well as rolling scale, filling materials,
forging scale, oxide films, etc. The ratio of minimum sheet thickness and stud diameter
amounts to 1:8.
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BMK-16 W
IMPORTANT INFORMATION
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.
• Drawn arc stud welding using ceramic ferrules as auxiliary aid.
• Drawn arc stud welding using shielding gas as auxiliary aid.
Preferably use shielding gas as auxiliary aid. The use of ceramic ferrules as auxiliary
aid, however, is necessary when carrying out particularly critical welding works as e.g.
welding works during which the gun has to be held in a horizontal position or above
the head.
2.1.1 Drawn arc welding with shielding gas
With this method, a gas mixture containing 82% of Argon and 18% of CO 2 (e.g.
Corgon®18*) is used as auxiliary aid.
This shielding gas protects the welding point from the atmosphere and simultaneously
supports the weld pool. Moreover, it ensures a concave fillet weld upset formation with
a blank metallic surface, thus reducing the risk of corrosion and obtaining an improved
dynamic behaviour of the welded joint.
An accurate bulging, to scale or in a calibrated or reproducible type, is not possible
when welding with shielding gas without using any auxiliary aid. Stud welding with
shielding gas can be carried out at much shorter intervals as no ceramic ferrules have
to be fitted and removed in each welding process.
*) Corgon®18 is a gas mixture of Linde AG in D-82049 Höllriegelskreuth
R
2.1.2 Drawn arc welding with ceramic ferrules
The ceramic ferrule fulfils the following functions:
• It centres the electric arc.
• It protects the welding point from the atmosphere.
• It ensures the exact formation of the weld upset.
• It prevents too rapid cooling of the weld pool.
• It protects against spraying sparks.
To ensure a perfect and accurate weld upset, each stud requires a ceramic ferrule
matching its diameter and shape. After every welding process, the ceramic ferrule
must be knocked down and replaced by a new one.
Usually this method allows you to weld in any position.
IMPORTANT INFORMATION
Ensure ceramic ferrules are absolutely dry.
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BMK-16 W
2.2 Stud welder set-up
The modular construction (modular principle) in useful and easy-to-service compact
housing, the modern design and progressive technique provide the SOYER stud
welder with its unique appearance.
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.
For information regarding the stud welding guns or welding heads to be used and their
setting, please refer to the respective operating instructions.
2.3 View / Dimensions
The BMK-16 W stud welder has a handy, compact and robust design. The two
carrying handles on the top of the housing allow easy transport so that the stud welder
can be used at different work places.
Illustration: Front view of BMK-16 W
Dimensions of BMK-16 W 410 X 330 X 600 mm (w x h x d)
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BMK-16 W
2.4 Technical data
Designation BMK-16 W
Welding process Drawn arc stud welding (DS)
Welding range SOYER threaded studs, DIN EN ISO 13918 from
M3 – M16 RD (MR) or Ø 2 – 13mm
Material Steel, stainless steel and heat-resistant steel (aluminium
conditionally depending on respective requirements)
Source of current Transformer / controlled rectifier bridge
Welding current 300 up to 1000 A
Welding time 10 up to 1000 ms
Welding sequence 15 – 30 studs/min. with M3
up to 3 studs/min. with M12 (Ø 11mm)
Standard gun PH-2L stud welding gun
Power supply
CEE 32 A (3P + safety earth conductor)
3 x 400 Volt 50/60 Hz (standard type)
3 x 230 Volt 50/60 Hz possible by carrying out reclamping
works
E-constant current 2 A / phase
E-constant power 1400 VA
E-peak current 120A / phase with 3 x 400 Volt (short-time operation)
Open-circuit power 78 Volt / DC
System of protection IP21
Fuse element at front
panel
F1 = 0.315 A slow F2 = 2 A slow (with 400V mains supply)
F2 = 3.15 A slow (with 230V mains supply)
Interfaces
Feeder interface: 15-pole socket
CNC interface: 9-pole socket
RS 232 interface: 9-pin plug (no function)
Compressed air
supply max. 6 bar (compressed air only with optional automatic set)
Shielding gas supply max. 4 – 5 l/min.
Dimensions 410 x 330 x 600 (w x h x d)
Weight* 68 kg
Colour RAL 5009 azure
Subject to technical changes
*Slight deviations are possible depending on accessories.
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BMK-16 W
2.5 Circuit diagram of BMK-16 W
2.5.1 Wiring diagram, primary (power circuit, 400 volt standard)
nc = no connection
Wiring Diagram (primary)
mains
filter
L3
L2
L1
PE
400vac
50/60Hz
32AT
5
7
2
6
8
2AT
main switch
D2
8V red +5V supply
230V
12V blue Ignition
12V black 1 SOW
8V black 2 sync
18V green +15V
supply
70V brown Magnet
(F2 front panel)
500V
control transfo
KL11 KL12
SO1200
holding loop
welding transfo (primary)
Y 400vac
R
S
T
X2
2
1
0V
6
2
3
4
5
230V
400V
440V
200V
1
7
8
D1
fan
230vac
1
blue
yellow/green
white/grey
grey
white/blue
white/pink
KL17
KL18
SO565
S14K250
3 4
30°v
brown
black
9
6 7
R S T
(F1 front panel)
315mAT
brown/black
brown/black
brown/green
HUM
yellow green purple
white/blue
white/pink
R
S
T
X
Y
Z
U
V
W
U
V
W
Z
X
Y
X1
230vac
R
S
T
X
Y
Z
U
V
W
U
V
W
Z
X
Y
X1
star point
R
S
T
white/blue
CA20X
white/blue
black black
sw
sw
X3
star point
Note:
When switching the welding transformer to 3~230V,
reclamp the control transformer at X3 and replace
the 2AT fuse at the front panel by a 3.15AT fuse.
(3.15AT)
(230vac)
X3
X3
X3
SO1200 machine PC board
154-902-XXX
mains supply
welding transfo (primary)
SOW = Stud on workpiece
Illustration: Primary wiring diagram, drawing no.: 154-902-XXX Subject to technical changes
2.5.2 Wiring diagram, secondary (welding circuit)
SO560/16 controller
Wiring Diagram (secondary)
KL30
KL31
SO1200
SO1200
KL20
KL21
KL13
KL14
earth +
earth
gun -
welding transfo
(secondary)
transformer
temp. protection
K5 G5
K2 K6 K4 K1
K3 G3 G1
G6 G2
G4
SO570
BMH
filter
solid-state relay
rectifier
LA1
LA2
LA3
R75
FD
R75
R
S
T
U
V
W
~
~
~
+
-
low
Hi
shunt
BNC
Pin7
control socket
7-pole
V2 V6 V4
V1V3V5
SO565
sync 180° R
S
T
Mp
L1
L2
L3
220vac
R
S
T
+-
yellow
yellow
17
18
10
5
15
16
1A
yellow
green
purple
white
10
SO560
red red redred
red red white
white whitewhite
white white
red blue
red
blue
red blue
black
blue
black
black
preweld current unit
red
yellow
150°C
+ cooler- cooler
154-902-XXX
earth +
Illustration: Secondary wiring diagram, drawing no.: 154-902-XXX Subject to technical changes
20