Soyer BMK-16i User manual

1
BMK-16i Operating Instructions
Stud Welder
GB: English Version
Read these operating instructions before starting any work!
Doc.ID: P00229
Date of issue: 12.2013
www.soyer.de

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3
Operating Instructions
BMK-16i Stud Welder
Serial number*
BMK-16i Stud Welder_________________________
Please enter the serial number here, so that the data is
immediately available if you need service support.
Order No.
Code designation
Note
P01340
BMK-16i
Mains voltage 3 x 400 V
P01341
BMK-16i Automatic
Mains voltage 3 x 400 V
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14 | 82237 Wörthsee | Tel.: [phone] | Fax: [phone] | E-mail: [email protected] | www.soyer.de

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Thank you!
Congratulations on purchasing the BMK-16i SOYER stud welder.
You have made an excellent choice. Your BMK-16i SOYER stud welder was specially developed for
the high-speed fastening of SOYER weld studs in compliance with DIN EN ISO 13918 on metallic,
weldable workpieces.
Our devices have been tested and proven according to current European and national
guidelines on health and safety. Proof of conformity has been established and the
manufacturer is in possession of the corresponding documents.
FOR YOUR SAFETY
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 distribute or reprint this document. It is also prohibited to exploit or disclose its
contents unless permission has been expressly granted. Non-compliance with this regulation will lead
to compensation for damages. 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 can vary in some details from your product. This,
however, has no influence on the handling of the machine.
The data in this documentation is verified regularly and any necessary corrections incorporated in
future impressions. Any suggestions for improvement are appreciated.
Date of issue: November 20, 2013
Rev.: May 2015
© Heinz Soyer Bolzenschweißtechnik GmbH 2013 · All rights reserved
Printed in the Federal Republic of Germany

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Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
82237 Wörthsee
EC Conformity Declaration
We herewith declare that the machine described in the following and the version available on
the market correspond in design and construction to the fundamental safety and health
requirements stipulated by EC Directive on Machinery. Any unauthorised modification to this
machine automatically annuls this declaration.
Designation of machine : Stud welder
Machine type : BMK-16i
Machine no. : ______________________
Applicable EC directives : DIN EN 60974-10
EC Directive on Low Voltage (2006/95/EC)
EC Directive on EMC (2004/108/EC)
Applied harmonised
standards, in particular : DIN EN 60 974 - 1
Applied national standards BGV A1, BGV A2, BGV A3, VBG 5,
and technical specifications,
in particular : VDE 0544
Date : 01 September 2010
Producer’s signature : ___________
Signer’s function : Managing Director

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Table of contents
1Safety instructions................................................................................................................ 8
1.1 Description of reference signs in the operating instructions ................................................ 10
1.2 Staff qualification and training.............................................................................................. 11
1.3 Dangers in the case of non-compliance with safety instructions......................................... 11
1.4 Before starting to weld... ...................................................................................................... 11
1.5 Working with the stud welding equipment............................................................................ 11
1.6 Inadmissible operating methods .......................................................................................... 11
1.7 Stopping the stud welding equipment.................................................................................. 11
2General................................................................................................................................. 12
2.1 The following should be principally observed... ................................................................... 12
2.2 Intended use ........................................................................................................................ 12
2.3 Marketing and service.......................................................................................................... 12
2.4 Information on the documentation ....................................................................................... 12
2.4.1 Information on the operating instructions ........................................................................ 12
2.4.2 Conduct in the case of malfunctions................................................................................ 13
3Description of stud welder................................................................................................. 14
3.1 Description ........................................................................................................................... 14
3.2 Radial-symmetric magnetic field stud welding (SRM Technology)...................................... 14
3.2.1 Drawn arc stud welding technology using shielding gas................................................. 15
3.2.2 Drawn arc stud welding technology using ceramic ferrules ............................................ 15
3.3 Technical data...................................................................................................................... 16
3.3.1 Wiring diagram BMK-16i.................................................................................................. 17
3.3.2 Wiring diagram - Components......................................................................................... 17
3.4 Interfaces BMK-16i............................................................................................................... 18
3.4.1 CNC interface .................................................................................................................. 18
3.4.2 RS 232-interface (SO-250 option)................................................................................... 18
3.4.3 Feeder interface............................................................................................................... 18
3.4.4 PG.Select......................................................................................................................... 19
4Installation of stud welding system .................................................................................. 20
4.1 Preparation of gas supply................................................................................................ 21
5Start-up................................................................................................................................. 22
5.1 Front- and rear view............................................................................................................. 22
5.1.1 Operating elements ......................................................................................................... 24
5.1.2 Display elements (LED displays)..................................................................................... 25
5.1.3 Description of display....................................................................................................... 25
5.1.4 Description of symbols..................................................................................................... 27
5.2 Preparation for start-up........................................................................................................ 27
5.2.1 Earth connection.............................................................................................................. 27
5.2.2 Connection of stud welding gun....................................................................................... 29
5.2.3 Gas supply....................................................................................................................... 29
5.2.4 Power supply ................................................................................................................... 29
5.3 Starting the stud welder ....................................................................................................... 29
5.3.1 Operating mode "OP" ...................................................................................................... 30
5.3.2 Operating mode "PRE" (preweld current test)................................................................. 30
5.3.3 Operating mode "LIFT" (lift test)...................................................................................... 31
5.3.4 Operating mode "GAS" (gas test).................................................................................... 31
5.3.5 Operating mode "MEAS" (Measuring) OPTION.............................................................. 32

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5.3.6 Electrode welding ............................................................................................................ 32
5.3.7 TIG welding...................................................................................................................... 33
5.4 Special functions – Submenus............................................................................................. 33
5.4.1 Special function "Deleting the main memory".................................................................. 33
5.4.2 Special functions – Extended submenu .......................................................................... 34
5.4.3 Special function "Display of operating counter"............................................................... 34
5.4.4 Special function "Setting the type of feeder and its functions" ........................................ 35
5.4.5 Special function "Setting the language"........................................................................... 36
5.4.6 Special function "Protocol/Log" (OPTION) ...................................................................... 37
5.5 Welding parameters............................................................................................................. 38
6Operation ............................................................................................................................. 39
6.1 Brief description ................................................................................................................... 39
6.2 Basic setting of the SRM stud chuck ................................................................................... 40
6.3 Basic setting of the SRM nut holder..................................................................................... 41
6.4 Start-up of PH-3N SRM stud welding gun ........................................................................... 43
6.5 Notes on the "Lifting test" operation mode........................................................................... 48
6.6 Welding operation with shielding gas................................................................................... 48
6.7 SRM welding operation........................................................................................................ 49
6.7.1 Stud welding with shielding gas....................................................................................... 49
6.8 Welding operation with ceramic ferrules.............................................................................. 50
6.8.1 Stud welding with ceramic ferrules.................................................................................. 50
6.9 Welding operation with quality control "MEAS" (OPTION) .................................................. 51
7Quality control (stud welding) ........................................................................................... 53
7.1 General instructions ............................................................................................................. 53
7.2 Test execution...................................................................................................................... 53
7.2.1 Production of samples ..................................................................................................... 53
7.2.2 Visual inspection.............................................................................................................. 53
7.2.3 Bend test.......................................................................................................................... 54
8Maintenance......................................................................................................................... 55
8.1 Important instructions........................................................................................................... 55
8.2 Important instructions for all service works.......................................................................... 55
8.3 Cleaning............................................................................................................................... 55
8.3.1 Detergents for cleaning the housing................................................................................ 55
8.4 Replacement of components ............................................................................................... 55
9Troubleshooting.................................................................................................................. 57
9.1 Malfunctions......................................................................................................................... 58
10 Transport and storage........................................................................................................ 61
11 Terms of warranty............................................................................................................... 61
12 List of standards and guidelines....................................................................................... 62

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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.
Only qualified persons are allowed to operate and maintain the equipment.
Children and juveniles under the age of 16 years must be kept away from the
equipment.
WARNING
It is prohibited to open the stud welding equipment.
The service personnel are required to meet special qualifications.
Our after-sales service has adequately trained personnel, suitable service equipment
and the means to carry out all necessary works.
Warning of electromagnetic fields
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, airbags).
Ensure that the welding equipment is not operated near electronically sensitive life-
support equipment, such as in intensive care units in hospitals.
Persons with pacemakers may neither operate the stud welding equipment nor stay in
the immediate vicinity while it is running.
Electric shock can cause death
Prevent electric shock by insulating your body from the working area and the ground.
Stand on dry insulating material and wear rubber soled shoes.
Inspect all cables including power cord for damage, wear or bare wiring.
Always ensure the correct supply voltage in accordance with the type plate.
Never connect the welding equipment to a power supply network with incorrect supply
voltage.
Always disconnect the welding equipment from the mains supply before starting any
cleaning works. Only trained and appropriately qualified personnel are allowed to carry
out works at the electric mains supply and welding system.
Do not touch live electrical parts with bare hand. Wear dry, hole-free insulating gloves.
Do not wear rings, watches or electrically conductive jewellery.
Keep the work area, studs, guns, cables, energy source as well as your clothes dry.

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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. Use adequate ventilation in the work area to remove
fumes and gases.
Welding can cause fire and explosions
Welding sparks and heat from flames and arcs can cause fires. Keep a portable fire
extinguisher within reach for immediate use. Be sure you are trained to use it.
When welding, do not wear clothes soiled with easily combustible substances such as
oil, grease and paraffin oil etc.
Comply with the fire regulations and do not weld, for instance, in hazardous locations.
Pay attention to flammable objects at the welding place. All flammable materials and
liquids, such as oil, fuel, etc. must be removed prior to the start of work.
Electronic equipment (e.g. airbags) and the use of explosive substances for fuel supply
require further safety precautions when carrying out welding operations on cars.
Appropriate information can be obtained from the trade associations or the car
manufacturers.
Skin and eye protection
Arc rays and welding spatters can injure eyes and skin.
Wear safety glasses with side shields and protective goggles with correct shade of filter
to protect your eyes from welding spatters and flashes of light that are generated during
the welding process.
Wear gauntlet gloves made of leather as well as non-combustible closed working
clothes such as heavy long-sleeve shirts, cuffless pants and safety shoes.
Wear a leather apron to protect your clothes from welding spatters.
Keep sleeves and collars buttoned and remove open pockets from the front side of your
clothing.
We recommend using ear protection. Some welding and working processes may
generate loud noises.

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1.1 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!
Warning!
Immediate hazards which could result in serious personal injuries or loss of
life.
Potential hazards which could result in serious personal injuries or loss of
life.
Caution!
Caution!
Potential hazards which could result in minor personal injuries.
Warning of damage.
Note!
Important!
Potential detrimental situation which may cause damage to the product or
to an object surrounding it.
Instructions for application and other useful information facilitating the
proper use of the product.
Safety symbols
The following pictographs for warnings, prohibitions and regulations are used in this manual:
Prohibited for persons
with pacemakers
Prohibited (only in
combination with an
additional safety symbol)
Do not touch
Housing is current-
carrying
Fire extinguisher
Warning of a danger
spot
Warning of dangerous
electric voltage
Warning of
electromagnetic field
Warning of moving
parts
General prohibition
(only in combination
with an additional
safety symbol)
Warning of inflammable
substances
Warning of explosive
substances
Eye protection required
Protective clothing
required
Ear protection
required
Protective gloves
required

General instructions are marked with the hand symbol.

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1.2 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 must be carefully regulated by the user. If your personnel do not have the necessary knowledge,
they must be trained and instructed. If necessary, this can be done by the manufacturer/supplier on
behalf of the user. Furthermore, the user must ensure that the contents of the operating instructions
have been fully understood by the staff.
The society of welding institutes (GSI: Gesellschaft der Schweißtechnischen Institute mbH) offers the
appropriate training courses for your personnel.
For information on branches, please refer to website http://www.dvs-ev.de.
1.3 Dangers in the case of non-compliance with safety instructions
The non-compliance with safety instructions may not only endanger persons, but also the equipment
and its environment. Any non-compliance with safety instructions may result in a complete loss of
damage claims.
The following dangers may result if the safety instructions are not complied with:
•Failure of important system functions.
•Failure of prescribed methods for maintenance.
•Danger to persons through electrical, mechanical, thermal and/or acoustic influences.
1.4 Before starting to weld...
•Check the state of all cables and cable connections before starting to weld.
•Immediately replace defective cables and cable connections.
1.5 Working with the stud welding equipment
Comply with all accident prevention regulations applicable to the operation of your welding device.
If an accident happens,
•switch off the welding device and disconnect it from the mains supply and.
•call a doctor.
1.6 Inadmissible operating methods
Limit values
The working safety of the stud welding equipment is only guaranteed when the system is used in
accordance with its purpose. The limit values indicated in the chapter “Technical data” must never be
exceeded.
1.7 Stopping the stud welding equipment
•Turn off the mains switch of the stud welding equipment.
•Disconnect the mains plug from the mains socket.
•In case of automatic operation, disconnect the compressed-air supply.
•Disconnect the earth cable from the stud welder.
•Disconnect welding gun or head from the stud welder.
•Roll up the cables without buckling them.
•Prevent the stud welder being operated by unauthorized personnel.
•Check welding cables and connections of the stud welder for damage such as burn-off,
mechanical wear etc. and have damaged parts replaced by the SOYER customer service.

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2 General
2.1 The following should be principally observed...
With the BMK-16i stud welder you have purchased a product which
•is state-of-the-art technology
•fully complies with the current safety requirements and
•ensures high performance.
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 start-up. Each operator should confirm this per signature.
•Prevent the stud welder being operated by unauthorized personnel.
•Only trained personnel may operate the stud welder.
2.2 Intended use
The BMK-16i SOYER stud welder allows you to weld pins and threaded studs from M3 – M16 or
Ø 2 - 13 mm and many other types of weld fasteners manufactured from steel, stainless steel and
aluminium.
If you need consultation or assistance in solving problems, please contact either our parent company
or our field engineers.
2.3 Marketing and service
If you have any questions regarding the operation of retrofits for special applications or if you require
service, please contact your responsible service office or the following address:
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
D-82237 Wörthsee
Tel.: [phone]
Telefax: [phone]
www.soyer.de
[e-mail]
2.4 Information on the documentation
The following operating instructions are supplied with the BMK-16i stud welder:
• Operating instructions for BMK-16i Order no.: P00229
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. All
obligations of Heinz Soyer Bolzenschweißtechnik GmbH result from the respective contract of
purchase. This contract also contains the complete and universally valid warranties. These contractual
warranty terms are neither extended nor restricted by the implementation of these operating
instructions.

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CAUTION
Do not carry out any actions on the stud welding equipment without specifically knowing
the operating instructions or the respective part. Ensure that only qualified and trained
personnel familiar with the operating instructions operate the system.
2.4.2 Conduct in the case of malfunctions
If malfunctions occur, first try to detect and eliminate the causes according to the list in the
"Troubleshooting" chapter of these operating instructions. In all other cases, contact our service
department.
If you require our service, please make sure that you supply us with the following information:
•Customer number
•Product designation / options
•Serial number
•Year of construction
•Material of stud and workpiece
•Stud dimensions
This information helps us save time and unnecessary costs, e.g. incurred by delivering the wrong
spare parts.

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3 Description of stud welder
3.1 Description
The BMK-16i SOYER stud welder is universally applicable for both manual and automatic operation.
Control via a serial CNC interface is possible.
The BMK-16i stud welder enables the storage of parameters for various welding tasks as welding
programs. These parameters can be recalled at any time. To simplify operation, it is possible to store
programs for different stud diameters. This allows a more rapid and simpler interchange of different
welding tasks. The integrated quality control (optional) allows the most important parameters of the
weld to be monitored and any welding faults to be reported when inadmissible deviations occur.
The stud welder is equipped with four keys, eight light-emitting diodes (LED) and a two-lined text
display at the front panel. The stud welder is adjusted via the keys. The operating state during welding
is shown by the light-emitting diodes and on the display.
The following welding methods are possible when using the BMK-16i SOYER stud welder:
● SRM stud welding
● 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
● Manual electric welding (electrode welding)
● TIG welding
The PH-2L stud welding gun with control cable and shielding gas equipment is the standard gun to be
connected to the BMK-16i stud welder. Optionally you may also connect the PH-3N, PK-0K and PH-
3N SRM stud welding guns. These operating instructions only refer to the BMK-16i stud welder.
For information regarding the stud welding guns to be used and their settings, please refer to the
respective operating instructions.
3.2 Radial-symmetric magnetic field stud welding (SRM Technology)
For operating the BMK-16i stud welder, we recommend using the patented SRM stud welding process
(patent no. 10 2004 051 389) in conjunction with the newly developed HZ-1 universal weld stud
featuring a plane end face and centring tip (patent no. 10 2006 016 553). This innovative welding
technique enables welds at a ratio of 1:10 from the sheet thickness to the stud diameter (previously
1:4). Furthermore there is no need to use ceramic rings during this process. The numerous
advantages delivered by the SRM procedure offer completely new potential applications, primarily in
the area of automated stud welding plants and large-scale component production (for additional
information, please refer to www.hz-1.com).
Further benefits of SRM welding include:
- No disturbing weld bead
- No ceramic ferrule required even in constrained positions (out-of-position welding)
- Reduced penetration in the sheet
- Less energy consumption and shorter welding time
- No weld spatters

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The stud comes into contact
with the workpiece and is
raised. The arc is triggered.
The arc is guided through the
spiral-shaped magnetic field
and completely melts both join
parts.
The stud immerses into the very
flat penetration zone and is
inseparably connected.
The above illustration shows the radial-symmetric magnetic field stud welding process (SRM).
With this welding method, we recommend using shielding gas as weld pool protection (e.g. a gas
mixture containing 82% of Argon and 18% of CO2).
3.2.1 Drawn arc stud welding technology using shielding gas
With this method, a gas mixture containing 82% of Argon and 18% of CO2(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
3.2.2 Drawn arc stud welding technology using 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 welding bead.
• It prevents too rapid cooling of the weld pool.
• It partially 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 off 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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3.3 Technical data
Designation BMK-16i
Welding process
Drawn arc stud welding (DA)
Electrode welding rectifier
Welding range
SOYER threaded studs, DIN EN ISO 13918 from
M3 - M16 RD (MR) or Ø 2 - 13 mm
Material
Steel, stainless steel and heat-resistant steel (aluminium
conditionally depending on respective requirements)
Power source Inverter technology
Welding current
100 up to 1000 A stud welding
40 up to 300 A electrode welding
40 up to 100 A TIG welding
Welding time 3 up to 1000 ms (only with operating mode "stud welding")
Welding sequence
15 - 30 studs/min. with M3
Up to 3 studs/min. M12 (Ø 11 mm)
Standard gun PH-2L stud welding gun (PH-3N SRM)
Power supply
CEE 32 A (3P + safety earth conductor)
3 x 400 V 50/60 Hz +10% -15%
E-continuous current 1 A / phase
E-continuous power 700 VA
E-peak current 90A / phase with 3 x 400 V (short-time operation)
Open-circuit voltage 80 V / DC (direct voltage)
System of protection IP21
Interfaces (option)
Feeder interface: 15-pole socket
CNC interface : 9-pole socket
RS 232 interface: 9-pin plug (with SO-250 option)
Ext. program selection PG.Select interface : 9-pole socket
Compressed-air supply max. 6 bar (compressed air only with optional automatic set)
Shielding gas supply max. 4 – 5 l/min.
Dimensions 335 x 440 x 700 (w x h x d)
Weight* 36.5 kg
Colour RAL 5009 azure
Technical specifications are subject to change without notice.
WARNING
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
the welding current circuit and not to the complete stud welding equipment.

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3.3.1 Wiring diagram BMK-16i
4
3
2
1
4
3
2
AB
C
D
E
ABCD
E
1
Ersatz durch:
Bearb.
Gepr.
Datum Name
Ersatz für:
Type
DatumZust. Änderungs-Nr. Name EDV-Nr:
Zeichnungs-Nr:
Alle Rechte nach DIN 34 vorbehalten
Blatt von Blätter
SOYER
Heinz Soyer
Bolzenschweisstechnik GmbH
Inninger Straße 14, 82237 Wörthsee-Ett erschlag
ME
5.11.02 Benennung:
Verdrahtungsplan
BMK16i
12
Timonta
Filter
L3
L2
L1
PE
L1
L2
L3
0V
230V
20V Versorgung
70VMagnet
Steuertrafo
INVERTER
Masse
DIL2
schw.
L3
L2
L1 +
-
Masse
Pistole
A1
A2
A7
A6
Gasventil
+
-
14Pol Flachkabel
X3 SO112
Stecker A
+
+
-
A8
T1
T2
T3
Schleife
14
a2
a1
4
3
x2
x1
DIL2
S1
<O>
<|>
F2 250mA
12 pol
575V6A
braun
braun
grün
grün
blau
blau
weiß
braun
rot
S1
br
ws
S1
13
400V
440V
1
2
grbr
br
ge
rt
ge ge
gr
F2
3,15AT
F1
3,15AT
schw.
ws
br
A9
A11 A10
A12
A3
A4
A5
S0 112
400Vac
50/60Hz
32AT
D.L.
A
17.01.08
159-902-001
Gültig ab Geräte Bj. 2008.
weiss weiss
4
2
1 3
SO 113
bl/ws
rt/ws 1
3
Stecker
4 pol.
SRM
Unit
6pol
24V
BV070301
+
-
64pol.SO112+SO100
Technical specifications are subject to change without notice
3.3.2 Wiring diagram - Components
15 Bu
9 Bu
9 Pin
RS 232 CNC Rüttler
Schnittstellen
SO112
Maschinenplatine
B1 B2 B3 B4 B5 B6
Kern25 2Wdg. weiss
gelb
violett
braun
schwarz
rot
6
1
3
4
5
2
Steuerbuchse
F1 3,15AT
1 2 3 4 5 6
Stecker B 6Pol
(Frontplatte)
F3 1,6A
F2 100mA
A1
A2
A3
A4
A5
A6
A7
A9
A10
A11
A12
Stecker A 12Pol
X1 VG64
X2 20Pol
X4 10Pol
X3 14Pol
Inverter
Ventile
Schnittstellen
D7
D10
D9D8
D5
D4
D3
D2
D6
D1
X4 20Pol
Schnittstellen
SO20
C11 1500µF
64Pol Flachkabel
X1 VG64
SO100
STEUERPLATINE
(FRONTPLATTE)
D7 D7
D7
D7
Inverter 14Pol Flachkabel
Option VENTILE
Option
9Pol Flachkabel
20Pol Flachkabel
X2 9Pol
9 Bu
Extern (Option)
+15V
+5V
Vstr. Hstr.
Schleife
+26V 70Vac 20Vac +Klemme frei
Gasventil
blau
blau grün grün
rot braun weiß
braun
Programm
Schleife
230Vac
grau sw gelb
-Magnet
+Magnet
Trigger
(AGND)
Trigger
Baw
+15V
Pistole
7Pol Tuchel
*BAW= Bolzen auf Werkstück
NC
*AGND= Analoge Masse
Technical specifications are subject to change without notice

18
3.4 Interfaces BMK-16i
3.4.1 CNC interface
The CNC interface serves for the control and communication e.g. in conjunction with a CNC stud
welding machine.
Circuit diagram of CNC interface
Description of CNC interface
PIN
Identification
Description
1+6
Start external
Contact releases the welding process.
2+7
Signal 1 (QUAKO option)
Weld is OK: Contact is present during operation. It is
interrupted in case of a faulty weld and can be reset with
"Reset external".
3+8
Signal 2 (SOW)
Stud onto workpiece
Contact is made when stud touches the workpiece.
4+9
Signal 3 (QUAKO option)
Final contact:
Contact is reset after welding e.g. in order to prevent an
external control from being released/started.
6+5
Reset external
Error reset, external
Contact resets error messages.
3.4.2 RS 232-interface (SO-250 option)
The RS 232 interface serves as a "printer interface" or as "remote control" e.g. in conjunction with a
CNC stud welding machine.
A complete device configuration for the central control via a PC is possible via the interface. Operation
via the four function keys is therefore no longer necessary.
3.4.3 Feeder interface
The feeder interface serves as the control and communication of our systems for the external stud
feed e.g. by means of an UVR-300 SOYER universal feeder.

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3.4.4 PG.Select
Communication interface for the P3-Select/S gun distribution system. This interface serves for the
automatic selection of programs (for further information, please refer to the operating instructions of
the P3-Select gun distribution system).

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4 Installation of stud welding system
The top of the BMK-16i stud welder 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 stud welder by means of a crane to the
installation site. The welding unit would become instable and might tilt from its
original position. As a result the handle could rip and the system would fall to
the ground.
•Only install the stud welder on an even surface. The pads located on the bottom of the
welding equipment guarantee its anti-skid position and serve as vibration dampers.
•Although the stud welder is resistant to environmental influences, it should be protected
against dampness and dust.
•Please pay particular attention to the bearing strength of the workshop furniture and ensure a
safe and stable position for the welding equipment.
•Make sure there is sufficient free space around the air apertures, otherwise the device safety
mechanism will respond and interrupt the welding process. This state, represented as "Unit
not ready" is shown alternately with the current operating mode on the display.
•Install the stud welder close to the welding location.
•Ensure correct connected loads for electrical connections:
Socket CEE 32A - 6h; 3 x 400 V~/ 50 Hz / 60Hz.
BMK-16i stud welder has a four-core connecting cable: 3P + safety earth conductor.
•Please observe that additional extension cables cause a voltage drop, possibly leading to
system disturbances.
•When welding with shielding gas, make sure the gas cylinder is installed safely in its
approved, accident-proof installation device.
NOTE
The housing of BMK-16i stud welder corresponds to safety class IP21. Please
observe that this system of protection is not suitable for being operated or
transported in the rain.