Soyer SRM EcoWeld BMK-20i User manual

Operating Instructions
Stud Welding Device
BMK-20i
GB: English Version
Read these operating instructions before starting any work!
Doc.ID: P00265
Date of issue: 06.2021
www.soyer.com

Operating instructions BMK-20i | Soyer Bolzenschweißtechnik 3
Device numbers
We recommend entering your device numbers here so that they can be
accessed quickly if servicing is required.
Device
Type
Serial number
Stud welding device
BMK-20i
Stud welding gun
PH-3N SRM
Stud welding gun
PH-2L
Stud welding gun
PH-4L
Operating Instructions
Document no.: P00265, 06-2021, translation of the original German manual
(German: P00165)
All information contained in this document is the property of Heinz Soyer
Bolzenschweißtechnik GmbH.
Revision status
Document
created / modified
Editor
Date
Original
Created
MS/IS
June 08th, 2021

4 Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik
CONTENTS
1General information.............................................................................................................. 6
1.1 Validity of the operating instructions ...................................................................................... 6
1.2 Registered trademarks........................................................................................................... 6
1.3 Abbreviations and definitions................................................................................................. 7
1.4 Declaration of conformity ....................................................................................................... 7
1.5 Manufacturer.......................................................................................................................... 9
1.6 Instruction, training................................................................................................................. 9
1.7 Standards and directives........................................................................................................ 9
2Important safety instructions............................................................................................. 10
2.1 Warning signs used.............................................................................................................. 10
2.2 General safety instructions................................................................................................... 11
2.3 Safety instructions for the working method.......................................................................... 14
2.4 Personal protective equipment ............................................................................................ 15
2.5 Intended use of the stud welding device.............................................................................. 16
Incorrect use.................................................................................................................... 16
2.6 Intended use of the stud welding guns ................................................................................ 16
Incorrect use.................................................................................................................... 17
2.7 Requirements on the part of the operator............................................................................ 17
Prerequisites for personnel.............................................................................................. 17
3Transport.............................................................................................................................. 18
4Storage, shutdown.............................................................................................................. 18
5Disposal ............................................................................................................................... 18
6Description of the BMK-20i stud welding device............................................................. 19
6.1 Type designation.................................................................................................................. 19
6.2 Working method................................................................................................................... 19
Stud welding with SRM Technology®.............................................................................. 20
Drawn arc stud welding technology using inert gas ........................................................ 21
Drawn arc stud welding technology with ceramic ferrules............................................... 22
6.3 Overview of the controls and connecting elements ............................................................. 23
Display and setting area .................................................................................................. 25
6.4 Technical data of the BMK-20i stud welding device ............................................................ 26
6.5 Permitted welding guns........................................................................................................ 27
6.6 Cleaning the stud welding system ....................................................................................... 28
7Description of stud chuck.................................................................................................. 29
7.1 SRM®stud chuck ................................................................................................................. 29
Setting the SRM®stud chuck........................................................................................... 29
7.2 Drawn arc stud chucks......................................................................................................... 31
8Description of the PH-3N SRM stud welding gun............................................................ 32
8.1 Technical data of the PH-3N SRM stud welding gun........................................................... 33
8.2 Installing the SRM®stud chuck in the PH-3N SRM welding gun......................................... 34
8.3 Cleaning the welding gun..................................................................................................... 36
9Description of the PH-2L and PH-4L stud welding guns ................................................ 37
9.1 Description of the PH-2L stud welding gun.......................................................................... 37
Technical data of the PH-2L stud welding gun................................................................ 38

Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik 5
Adjusting the speed of immersion (damping) for PH-2L.................................................. 39
9.2 Description of the PH-4L stud welding gun.......................................................................... 40
Technical data of the PH-4L stud welding gun................................................................ 41
Adjusting the speed of immersion (damping) for PH-4L.................................................. 42
9.3 PH-2L and PH-4L stud welding guns with SRM Technology®............................................. 43
How to retrofit the PH-2L and PH-4L stud welding guns to SRM Technology®.............. 45
9.4 PH-2L and PH-4L stud welding guns with drawn arc & inert gas ........................................ 47
How to retrofit the PH-2L and PH-4L stud welding guns to drawn arc welding with inert gas
......................................................................................................................................... 48
9.5 PH-2L and PH-4L stud welding guns with drawn arc & ceramic ferrule.............................. 50
How to retrofit the PH-2L and PH-4L stud welding guns to drawn arc welding with ceramic
ferrule ......................................................................................................................................... 51
9.6 Cleaning the welding gun..................................................................................................... 54
10 Setup and connection......................................................................................................... 55
10.1 Requirements for the installation site................................................................................... 55
10.2 Connection of the stud welding device and the stud welding guns ..................................... 56
Mains connection......................................................................................................... 56
Connecting the earth cable ......................................................................................... 56
Connecting the stud welding gun ................................................................................ 57
Connecting the inert gas supply.................................................................................. 57
11 Settings ................................................................................................................................ 61
11.1 Setting welding parameters.................................................................................................. 61
Support tables for device settings ............................................................................... 62
Setting the welding current and the welding time........................................................ 64
Setting/deactivating the SRM®current........................................................................ 65
Setting the gas preflow time (gas test)........................................................................ 66
Setting the lift height (drop time) in the "Setup" mode ................................................ 67
12 Welding operation............................................................................................................... 69
12.1 Carrying out welding ............................................................................................................ 69
12.2 Notes on checking the quality of the weld............................................................................ 71
Visual inspection.......................................................................................................... 71
12.3 Switching off the device ....................................................................................................... 72
12.4 Welding defects and their causes........................................................................................ 73
13 Maintenance and repair...................................................................................................... 77
14 Service.................................................................................................................................. 77
15 Spare and conversion parts............................................................................................... 78
15.1 Spare and conversion parts for drawn arc welding with ceramic ferrules ........................... 78
16 Warranty conditions ........................................................................................................... 79

6 Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik
1 General information
These operating instructions contain important information and rules for the operation
of the devices. Keep the operating instructions in a readily accessible location close to
the devices.
The term 'Devices' in the operating instructions refers to the stud welding device and
the stud welding gun.
Carefully read the operating instructions and any other documents contained in the
technical documentation. Pay particular attention to the safety instructions which are
intended to help you recognise any possible residual risks and prevent hazards.
The drawings and diagrams in these operating instructions are for illustration purposes
and may vary slightly from the actual equipment.
The manufacturer reserves the right to make technical changes.
1.1 Validity of the operating instructions
These operating instructions apply to the following devices:
Stud welding device BMK-20i
Stud welding gun PH-3N SRM
PH-2L
PH-4L
1.2 Registered trademarks
The following terms in these instructions are used with registered trademarks:
SRM®:
SRM Technology®
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.

Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik 7
1.3 Abbreviations and definitions
Essential abbreviations or designations in this manual:
HZ-1 threaded studs: SOYER®universal weld studs with centring tip
MF threaded studs: SOYER®threaded studs with a reduced flange
diameter (MF stands for mini flange).
PT threaded stud Capacitor discharge welding studs with thread
IT tapped studs Capacitor discharge tapped studs
RD threaded studs Drawn arc welding studs with thread
1.4 Declaration of conformity
The devices are designed and constructed in accordance with the generally accepted
codes of practice.
Please note that significant changes to the device will cause the declaration of
conformity to become void.
Furthermore, the manufacturer's warranty may be rendered invalid.

8 Operating instructions BMK-20i | Heinz 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-20i
Machine no. : ______________________
Applicable EU directives : RoHS Directive (2011/65/EU)
Low Voltage Directive (2014/35/EU)
EMC Directive (2014/30/EU)
Applied harmonised : EN 60 974-1:2018 + A1:2019
standards, in particular EN 60 974-10:2016
Applied national standards : DGUV Regulation 1
Date : 01 February 2021
Producer’s signature : ____________________
Signer’s function : Managing Director

Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik 9
1.5 Manufacturer
The manufacturer of the devices is:
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
82237 Wörthsee
Phone: [phone]
Fax: [phone]
Email: [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.
Moreover, SOYER®offers training for customer-specific use of the devices.
Information on the scope and costs of instruction and training can be obtained
from Soyer GmbH.
1.7 Standards and directives
The following standards, inter alia, 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 operators and
weld setters for mechanised and automatic welding of metallic materials
DIN EN IEC 60974-9 Arc welding equipment - Installation and use
Technical Bulletin DVS 0904 Instruction for practice - Arc stud welding

10 Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik
2 Important safety instructions
Read the following chapters carefully and follow the safety instructions. If you are
uncertain or if an instruction cannot be followed, please contact the manufacturer.
The devices have been constructed according to the generally accepted codes of
practice and in compliance with, and application of, the recognised safety requirements.
To achieve the greatest possible safety, it is essential that all of the safety instructions
in these operating instructions are heeded and followed.
2.1 Warning signs used
Warning signs are used in this document, depending on the potential danger of the
situation.
Safety and information symbols used in this manual
Imminent danger leading to severe injuries or death.
Potentially dangerous situation that may lead to severe
injuries or death.
Potentially dangerous situation that may lead to minor
injuries.
Without the warning triangle, this warning sign is also
used in the event of danger of material damage.
Additional information indicating danger from electric
current. The additional sign is used in conjunction with
a warning sign.
Additional sign indicating the danger of burns. The
additional sign is used in connection with a warning
sign.
Do not touch the surface or the housing: Risk of electric
shock.
Do not touch or open, danger to unauthorised persons.
Danger to persons with medical implants such as
pacemakers.
The information sign is not a warning sign. It indicates
important and useful information on the subject.

Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik 11
Safety instructions on the devices
As an additional warning of danger, warning labels can be found on the devices.
Warning labels are affixed by the manufacturer and must not be removed. If a warning
label is damaged and thus illegible, a new warning label must be affixed immediately.
Warning labels must be obtained from the manufacturer.
2.2 General safety instructions
Danger from electric current, general information
When working on live components, there is a danger to life from electric current.
Work on electric or electronic components may only be performed by trained
electrotechnical personnel in accordance with currently applicable
electrotechnical regulations.
Protective devices must not be manipulated or disabled. Protective devices
include, for example, housing and housing cover, fuses or power switches.
If protective devices have to be removed for maintenance work, the device
may only be switched on again when all protective devices are installed and
their functionality has been checked.
Starting the device with faulty protective devices is not permitted. Faulty
protective devices must be repaired or replaced immediately. Unintentional
operation by third parties must be prevented.

12 Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik
Danger from electric current during maintenance and repair
When working on live components, there is a danger to life from electric current.
Work on electric or electronic components must only be carried out by trained
electrotechnical personnel of Soyer Bolzenschweißtechnik.
Before performing any work on the stud welding device, the mains switch of
the device must be switched off and the mains plug of the stud welding
device must be disconnected.
Before performing any work on the stud welding gun, the supply cables to
the stud welding device must be disconnected.
If protective devices have to be removed for maintenance work, the device
must only be switched on again when all protective devices are installed and
their functionality has been checked.
Danger from magnetic fields
In the area surrounding the device, strong magnetic fields occur during the welding
process. These may influence medical auxiliary aids and can therefore result in
danger to life.
Persons with electrical medical aids (such as pacemakers) must keep away
from the devices.
The operating personnel must ensure that persons with medical aids keep
away from the devices.
Danger of explosion from an inappropriate installation site in explosive
atmospheres
The device is not designed for use in potentially explosive zones.
The device must not be installed and operated in potentially explosive
atmospheres.

Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik 13
Risk of burns due to hot surfaces
During the welding process, the workpieces and some parts of the welding gun get
so hot that touching them may cause burns.
Always use personal protective equipment.
Before working on hot parts of the device, check that they have cooled down.
Do not hold the gun in the welding area.
Risk of burns from hot welding spatter
Dangerous welding spatter can occur during the welding process.
Always use personal protective equipment.
Fire hazard from hot welding spatter
Welding spatter or hot workpieces produced during the welding process can result in
fire hazard.
Do not store combustible or highly inflammable materials in the welding area.

14 Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik
2.3 Safety instructions for the working method
Hazards due to incorrect working method
Hazards for operators and third parties can arise due to an incorrect working method.
Ensure sufficient stability and a dry installation location for the device.
Make sure you do not knock over the device or pull it down from its position
with the gun cables.
Make sure, especially with mobile use, of your own good stability during
welding.
Do not hold the workpiece in your hands during welding. The workpiece must
be securely fixed during the welding process.
Never wrap the gun lines around parts of your body (e.g. arm) as electric
fields can occur.
If the gun is not positioned properly or the gun settings are incorrect, a flash
can occur during welding. Do not look directly into the flash.
The gun carries out lifting movements during the welding process. Do not
hold the gun tight in the area of moving parts.

Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik 15
2.4 Personal protective equipment
It is recommended to wear personal protective equipment when working with the stud
welding device.
Danger due to a lack of or incorrect PPE
During stud welding, there is a risk of burns, especially due to hot welding spatter.
The formation of strong electric arcs can also cause a glare hazard.
Always wear suitable, closed protective clothing.
Type and extent of the protective equipment depends on the respective
occurrence and intensity of welding spatter, arcs and/or noise. This varies
depending on the basic material, stud material, stud size and required
welding performance.
Please observe the following instructions for protective equipment.
Recommended personal protection equipment
Protective goggles
During welding, welding spatters and a flash of light
occur. Wear appropriate safety goggles with side
protection and a filter protector, if necessary.
Protective gloves
During welding, the workpieces and parts of the welding
gun get hot and welding spatters occur. Wear
appropriate, non-combustible, heat-resistant protective
gloves.
Protective clothing
Welding spatters occur during the welding process.
Wear appropriate, non-combustible and, if necessary,
heat-resistant, protective clothing.
Safety shoes
Welding spatters occur during the welding process.
Wear appropriate, non-combustible, heat-resistant
safety footwear.
Hearing protection
Depending on the welding device and the welding
application, relatively loud welding noises may occur.
Wear appropriate hearing protection.

16 Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik
2.5 Intended use of the stud welding device
Pins and threaded studs from M3 - M16 made of steel and stainless steel can be welded
using the SOYER®BMK-20i stud welding device (M16 preferred with SOYER®HZ-1
weld studs and SRM Technology®).
Special studs or diameters on request.
The stud welding device must only be operated with the welding guns described in
chapter “6.5 Permitted welding guns” on page 27.
The stud welding device must be operated within the technical specifications.
Only welding studs according to DIN EN ISO 13918 and SOYER®standard may be
welded.
The stud welding device supports the following welding processes:
SRM® welding (stud welding in a radially symmetrical magnetic field)
Drawn arc stud welding with inert gas
Drawn arc stud welding with ceramic ferrules
Incorrect use
Any use of the device deviating from the intended use is considered improper use.
Improper use, unauthorised modification or manipulation of the device will void the
declaration of conformity and all warranty claims against the manufacturer.
2.6 Intended use of the stud welding guns
With the SOYER®stud welding guns described in these operating instructions, pins and
threaded studs from M3 to M16 as well as many different weld fasteners made of steel
and stainless steel can be welded according to the DIN EN ISO 13918 and SOYER®
standards.
The maximum diameter and type of weldable studs can be limited by the
performance capacity of the stud welding device on which the gun is operated.
Special studs or diameters on request.
The operation of welding guns is only permitted with the stud welding devices described
in the technical data of the gun.
The stud welding gun must be operated within the technical specifications.

Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik 17
Incorrect use
Any use of the welding gun deviating from the intended use is considered improper
use.
Non-intended use, unauthorised modification or manipulation of the device will void the
declaration of conformity as well as all warranty claims against the manufacturer.
Misuse of the welding gun as a tool, e.g. as a hammer for checking the weld quality, is
not permitted.
2.7 Requirements on the part of the operator
The operator of the device must ensure that the preconditions described in this
operating manual regarding safe operation of the device are met.
These include, for example, the conditions at the installation location, regulatory
requirements for a safe workplace, training of the operating personnel and qualified
personnel in using the device, if applicable, compliance with required maintenance work
as well as monitoring the intended use of the device.
These operating instructions must be stored in the vicinity of the stud welding device.
The operator of the device must ensure that all protective devices are present, active
and intact before the stud welding device is used.
Please observe the DIN EN IEC 60974-9 standard (arc welding equipment - part 9:
Installation and operation) in the currently valid version.
Prerequisites for personnel
Operating personnel
The persons authorised to operate the device must be familiar with the stud welding
device and trained accordingly. They must have read and understood these operating
instructions. When working with the stud welding device, they must also be able to avert
possible residual danger to themselves and third parties or minimise them as far as
possible.
To maintain the qualification, safety training must be carried out at least once a year. In
the event of malfunction or for maintenance, specially trained personnel or the
manufacturer must be consulted, if necessary.
Operators of stud welding equipment must have technical expertise for operating and
adjusting the devices properly as well as for properly carrying out weldings.
If welding personnel have to be qualified for certification of welding, the DIN EN ISO
14555 and DIN EN ISO 14732 standards are to be observed.

18 Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik
Trained electrotechnical personnel
In general: Work on live elements may only be performed by authorised electricians.
This work must be performed in line with the applicable technical rules for
electrotechnical devices.
All devices of Soyer Bolzenschweißtechnik GmbH must only be opened by
SOYER®personnel or personnel authorised by SOYER®.
3 Transport
When transporting the device, make sure it cannot be damaged. Use appropriate
packaging to protect the device against weathering effects, especially moisture.
Danger during transport
The device is equipped with a handle and carrying strap on the top. The handle and
carrying strap are intended exclusively for transport by hand. Never pull ropes
through the handle or carrying strap to lift the stud welding device by means of a
crane to the installation site. The welding device would become instable and might
tilt from its original position. As a result the handle or carrying strap could rip and the
unit could fall to the ground.
4 Storage, shutdown
During storage or shutdown, make sure to protect the device against dirt and humidity.
Protect the stud welding device against unauthorised access by third parties.
5 Disposal
Local environmental directives must be observed when disposing of the device.
Water-endangering as well as environmentally hazardous substances are to be
disposed of in accordance with legal regulations.
If applicable, materials must be separated according to regulations.

Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik 19
6 Description of the BMK-20i stud welding device
The main elements of the stud welding device and their function are shown and
described in the following.
6.1 Type designation
Designation
Order number
Feature
BMK-20i
P01347
Mains voltage
3 x 400 V, 50/60 Hz, 32 AT
6.2 Working method
With the SOYER®BMK-20i stud welding device, pins and threaded studs from M3 to
M16 or Ø 2 - 16 mm (M16 preferred with SOYER® HZ-1 weld studs & SRM Technology®)
made of steel and stainless steel can be welded.
Only welding studs from SOYER®(preferably HZ-1 and MF types) may be welded.
Fasteners from other manufacturers must be approved by SOYER®.
The BMK-20i stud welding device operating with SRM Technology® was specially
developed for mobile use. Thanks to SRM®, it enables problem-free welding, even
under difficult conditions.
The BMK-20i stud welding device operates on the basis of a compact inverter power
source and provides a constant welding current from 100 A to 1200 A at welding times
from 20 ms to 500 ms. The rectified mains voltage is converted into high frequency
voltage with a frequency of 75 kHz by an Insulated Gate Bipolar Transistor-based
(IGBT-based) inverter. The energy is transferred by a high frequency transformer and
rectified on the output side. As a result of the high control speed in combination with the
integrated SRM®welding process of the BMK-20i, the reproducibility of the welds is
increased and the quality of the welds considerably improved.

20 Operating instructions BMK-20i | Heinz Soyer Bolzenschweißtechnik
Stud welding with SRM Technology®
The welding procedure recommended by SOYER®for operating the BMK-20i is the
patented SRM®welding procedure (patent no.: 10 2004 051 389) in conjunction with
the HZ-1 universal weld stud with a plane end face and centring tip (patent no.: 10 2006
016 553).
SRM®stands for stud welding in a radially symmetric magnetic field. This innovative
welding technology allows for welding in a ratio of 1:10 of the sheet metal thickness to
the stud diameter (previously 1:4) where the use of ceramic ferrules can be dispensed
with.
The various advantages of the SRM®procedure open up completely new possible
applications in the entire stud welding sector.
Functional principle
The stud tip touches the
workpiece and is lifted.
The arc is initiated.
The ignited arc is guided
by a magnetic field and
melts both joint parts
fully.
The stud immerses in the
very flat weld penetration
zone and is solidly
connected.
The advantages of the SRM®welding process are:
No bothersome weld bead
Welding from constrained positions now also without ceramic ferrule
Reduced weld penetration in the plate
Lower energy consumption and reduced welding time
No welding spatter
For stud welding with SRM Technology®, a gas mixture is used as an aid.
Following inert gas mixtures are recommended:
82% argon and 18% CO2(standard inert gas)
90% argon and 10% CO2 (preferably with Ø ≥ 12 mm)
85% argon and 15% CO2