Operating Instructions BMH
Contents
1. 52 e 91 368 EEC formerly 89 392 EEC e 3 23 EEC 89 336 EEC e DIN EN 292 1 eDIN EN 292 2 e EN 60204 1 formerly VDE 0113 EN 60974 1 DIN VDE 0544 1 e VBG 1 e DIN EN ISO 14555 e DIN EN ISO 13918 e DIN 50049 e DIN 50125 EC Directive on Machinery EC Directive on Low Voltage EC Directive on Electromagnetic Compatibility Safety of machinery basic terms general principles of construction Part 1 basic terminology systems engineering Safety of machinery basic terms general principles of construction Part 2 technical principles specifications Electric equipment of machinery general requirements Safety requirements for arc welding equipment part 1 welding current sources General instructions instructions for accident prevention Arc welding of metallic materials Studs and ceramic ferrules for arc welding Certificate on material tests Testing of metallic materials tensile tests guidelines for production e DVS Information Sheet 0902 Drawn arc stud welding e DVS Information Sheet 0903 Capacitor discharge stud welding with tip ignition e DVS Information Sheet 0904 Practical information Arc stud welding Date of issue2. SOYER is a registered trade mark of Heinz Soyer Bolzenschweiftechnik GmbH It is prohibited to transmit or reprint this document as well as to utilize or disclose its contents unless this has been expressly granted Non compliance with this regulation is liable to compensation All rights reserved particularly in the case of a patent grant or a GM registration We have verified that the contents of this pamphlet correspond to the hard and software described Deviations however cannot be excluded so that we cannot warrant for absolute compliance The illustrations contained in this instruction manual may vary in some details from your product This however has no influence on the handling of the machine The data in this documentation have been verified regularly and necessary corrections will be incorporated in future impressions Any suggestions for improvement will be appreciated Date of issue January 02 2006 Revision Heinz Soyer Bolzenschweik amp technik GmbH 2005 All rights reserved Printed in the Federal Republic of Germany BMH 221 soyer Table of contents 1 1 1 2 1 3 1 4 1 9 1 6 1 7 2 1 2 2 2 3 2 4 2 4 1 2 4 2 3 1 3 2 3 2 1 3 2 2 3 3 3 3 1 3 3 2 3 4 3 5 5 4 4 1 Safety Pl CC AU GINS nisceva aa ai aia 7 Description of reference signs in the operating iNStructions cccsseecccsseeeseaneseessaeeseees 9 Staff qualification and UAINING 11c
3. Welding time 3 up to 1000 ms only with operation mode stud welding Welding sequence up to 50 studs min depending on the respective stud diameter Standard gun PH 5L stud welding gun Power Sol CEE 63 A 3P protective earth conductor ppY 3 x 400 V 50 60 Hz 10 15 180A phase with 3 x 400 V short time operation Open circuit voltage 85 V DC direct voltage System of protection IP21 W Feeder interface 15 pole socket option optional automatic set CNC interface 9 pole socket option P RS 232 interface 9 pin plug option Compressed air supply max 6 bar compressed air only with optional automatic set Shielding gas supply max 4 5 l min Weight 70 kg Subject to technical changes Slight deviations are possible depending on accessories 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 welder 17 BMH 221 4 Installation of stud welder The top of the BMH 22i stud welder is equipped with two carrying handles CAUTION The carrying handles are intended for transport by hand only Never pull ropes through these handles to lift the stud welder by means of a crane to the installation site The stud welder would become instable and might tilt from its original position As a result the handles could rip and
4. 14 15 16 17 18 19 20 21 22 23 BMH 221 13 14 15 16 Iy 18 19 O 23 22 21 Rear view of BMH 22i stud welder 9 pole connection for external program selection option This interface serves to be connected with an external control system for controlling the welding parameters Danger sign 15 pole connecting socket Feeder interface option The feeder interface serves to connect the feeder control to the stud welding device 9 pole connecting socket CNC interface option The CNC interface serves to be connected with an external control system for controlling the stud welding process 9 pin connector interface RS 232 option This interface serves to be connected with an external control system Safety label Type plate Connection for STG 1 control device option This connection serves to connect the STG 1 control device to the stud welder Shielding gas connector This connection serves to supply the stud welder with gas by means of a pressure regulator The admissible gas flow value ranges between a maximum of 4 and 5 l min Compressed air supply connection option This connection serves to supply the stud welder with compressed air and to connect the compressed air leads of the feeder control to the stud welder The admissible supply pressure amounts to a maximum of bar Mains cable The mains cable is a four core 3P PE highly flexible connecting cable for connecting the stud welder to the ma
5. 3 2 1 Operation mode OP operating state The operation mode OP allows normal welding operation with the welding parameters set e Use the function key arrow up or arrow down 1 or 2 to set operation mode OP MODE PG MC MCT PCT GPT ALT OP L 200 3 40 0 0 BM gt 1 or 2 3 or 4 5 3 2 2 Operation mode PRE preweld current test The adjustment PRE preweld current test enables you to carry out welds by means of the set parameters without application of main current and serves to control the gun or head adjustment and to test performance During this operation mode an arc is generated with low current when the gun or welding head is positioned on the closed circuit workpiece connected with earth and the gun switch is pressed or when a signal is given via the interface This is helpful to check the symmetry of the arc or whether preweld current is flowing CAUTION Protective goggles are required to carry out this test Please also refer to the safety instructions MODE PG MC MCT PCT GPT ALT PRE 1 300 3 40 o o BM gt 1 or 2 3 or 4 5 3 2 3 Operation mode LIFT lift test This operation mode enables you to adjust and check the lift of the gun or welding head For further information please refer to the operating instructions of the welding gun or welding head e Use the function key arrow up or arrow down 1 or 2 to set operation mode LIFT 2 BMH 221 Test lift with trig
6. Linde AG in D 82049 Hollriegelskreuth 3 2 2 Drawn arc welding with ceramic ferrules The ceramic ferrule fulfils the following functions e It centres the electric arc e It protects the welding point from the atmosphere e It ensures the exact formation of the weld upset e It prevents too rapid cooling of the weld pool e 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 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 3 3 Manual electric welding TIG welding Instructions on application These operating instructions only describe the function stud welding Instructions on manual electric welding TIG welding can be obtained from the respective manufacturers of the necessary accessories 14 BMH 221 soyer Table for electrical characteristic values as per DIN EN 60974 1 10 40 A 21 6 V up to 300 A 32 V 11 11b 11c X 60 100 12b 12c 300 A Aoo A Uo 85 V 13b D a Field 6 Graphical symbol for the welding process Covered Electrode Manual Arc Welding Field 7 Symbol for welding current sources which are suitable for welding in an environment of increased electrical danger Field 8 Symbol for direct current Field 9 Ra
7. and compressed air supply from the stud welder e Roll up the cables without buckling them e Prevent the stud welder being operated by unauthorized personnel 10 BMH 221 soyer e Check welding cable 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 2 General 2 1 The following should be principally observed With this stud welder you have purchased a product which e is state of the art technology e fully complies with the current safety requirements and e enables successful working Before installing the stud welder please observe the following e Store the operating instructions in a place accessible to every operator e Ensure that the respective operator has read and understood the operating instructions prior to start up Each operator should confirm this per signature e Prevent the stud welder being operated by unauthorized personnel e Only trained personnel may operate the stud welder e Call a doctor in case of an accident 2 2 Intended purpose The BMH 22i SOYER stud welder for drawn arc welding allows SOYER threaded studs as per DIN EN ISO 13918 and ranging from M8 M24 RD MR or 8 22 mm 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 w
8. flow rate to a maximum of 4 5 l min 6 2 2 Instructions for welding with shielding gas e Set the parameters required for your welding task according to the table 1 Foot plate 2 Gas shroud 3 Welding stud Depth of immersion Illustration Stud welding with shielding gas 3 40 BMH 221 soyer e Set gas flow rate to a value between 4 and 5 l min If the value is too high the arc is extinguished if the value is too low the protective function of the gas is reduced Welding results are poor in both cases e Insert a stud into the welding gun or welding head A DANGER Never touch stud or stud holder during the welding process These components are current carrying e Position welding gun or welding head vertically on the workpiece when welding e Actuate the trigger e When welding with shielding gas the welding point is rinsed during the welding process as well as before and after welding for the period adjusted The LED Gas valve open indicates that the gas valve is activated The LED Final contact indicates that the welding process is completed 6 3 Welding operation with ceramic ferrules The measures mentioned in the Start up of stud welder chapter have already been performed Foot plate Ceramic ferrule Welding stud w N Illustration Stud welding with ceramic ferrule eo Welding operation with ceramic ferrules is only possible when using SOYER drawn arc weld
9. 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 Non compliance with safety instructions may have the following consequences e Failure of important system functions e Failure of prescribed methods for maintenance e Danger of persons through electric mechanic thermal and acoustic influences 1 4 Before starting to weld e Check the state of all cables and cable connections before starting to weld e Immediately replace defective cables and cable connections e Ensure that the air apertures of the housing are not covered Heat accumulation may damage the stud welding device 1 5 Working with the stud welding equipment e Comply with all accident prevention regulations which apply to the operation of your stud welding device If an accident happens e switch off the welding device and disconnect it from the mains supply e call a doctor 1 6 Inadmissible operating methods Limit values Working safety of the stud welding equipment supplied can only be 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 welder e Press the red OFF button 0 e Disconnect the mains plug from the socket e Disconnect the control cable the welding cable the earth cables possibly existing gas supply
10. only weld in rooms which are higher than 3 m Please also observe the safety regulations applicable for your country Do not breathe fumes and gases Use adequate ventilation in the work area to remove fumes and gases e g ventilating fan Exhaust welding fumes if necessary Welding can cause fire and explosions Welding sparks and heat from flames and arcs can cause fires Have a portable fire extinguisher handy for immediate use Be sure you are trained for properly using 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 and non combustible close
11. or unsteady welding position of welding gun Stud flange is not completely welded and shows visual defects Weld undercuts are visible E Oe Poor weld quality e g caused by excessive welding energy or insufficient plunge or lift Reduced diameter weld Partial weld T SSS 44 BMH 221 7 3 3 Bend test The bend test is a simple work test which serves to roughly check the setting values selected The welding zone is subjected to undefined tension pressure and bending A minimum of 3 studs is welded and bent by means of a tube that is slipped over the stud The test is successful when no superficial fissure or fracture is detected in the welding zone In drawn arc and short cycle drawn arc operation with ceramic ferrule or shielding gas the LS stud should be bent 60 from its axis Bend test with tube placed upon the stud Bend test with hammer 7 3 4 Tensile test The tensile test serves to test the metallic bond of the stud with the base metal At least 3 studs are welded and then axially loaded by means of an appropriate tension device until they break If the customer demands that a certain percentage of the welded studs should be tested with a specific test load in production a tension device with load indicator should be used If the stud breaks outside the welding zone the test is regarded as successful If it breaks within the welding zone an examination of the fractured surface helps to find out the appropriate c
12. power data Supply voltage current consumption on the type plate with the data supply voltage fuse protection of your power supply network Always ensure the correct supply voltage in accordance with the type plate Never er connect the stud welding device to a power supply network with incorrect supply voltage e Connect mains cable to power supply using the CEE plug DANGER Only connect stud welder to approved CEE sockets Standard connection 3 x 400 V protective earth conductor 63A CEE If need be have an expert in electrics check if the socket is earthed 5 3 Adjustment of operation modes 5 3 1 Starting the stud welder After switching the stud welder on the 8 LED lamps light up for a short period The stud welder carries out a self test which is shown on the LED display self test KE Oa E The stud welder is locked during the self test and it is impossible to operate it or to enter data After the self test has been carried out successfully the stud welder automatically sets the parameters which were last set 5 3 2 Operation modes parameters Press the function key arrow right or arrow left 3 or 4 to select the parameters Only the parameter designation which is flashing on the display can be set by means of the function keys 1 or 2 MODE PG MC MCT PCT GPT ALT A E a 1 or 2 4 or 4 The different operation modes possible have already been briefly described 26 BMH 221 soyer 5
13. protecting the lifting magnet to react and the current supply for the magnet to be interrupted This condition is displayed as follows 28 BMH 221 Lift test carried out too long 1 minute to cool lifting magnet 5 3 2 4 Operation mode GAS gas test This operation mode checks whether the shielding gas flows through the gas shroud of the welding gun or welding head As long as a triggering signal is there shielding gas flows out of the gas shroud on the welding gun or welding head This enables you to rinse the gas lines with shielding gas before starting to weld e Select the operation mode GAS with the function key arrow up or arrow down 1 or 2 MODE Test gas with trigger ITET GAS Be gt 1 or 2 e Connect gas supply e The gas valve may be activated by the trigger of the welding gun or welding head an active start signal at the CNC interface dl y i y wo g oe eo e KZ 2044 5 3 2 5 Operation mode Electrode welding In the operation mode Electrode welding the stud welder works like a welding rectifier CAUTION In this operation mode an open circuit voltage of about 80V DC voltage is always applied to the terminals e Use the function key arrow up or arrow down 1 or 2 to set operation mode ELECTRODE WELDING Leith jd E Current Y qirirtia Electrode welding 80 y Eain He iE 1 or 2 29 BMH 22 Use the function key arrow right 4 to se
14. the system would fall on the ground e Only install the stud welder on an even surface The anti vibration pads located on the bottom of the welding equipment guarantee its anti skid position and serve as vibration dampers e Although the stud welder is resistant to environmental influences it should be protected against dampness and dust e Please pay particular attention to the bearing strength of the workshop furniture and ensure a safe and stable position of the welding equipment e Make sure there is sufficient free space around the air apertures otherwise the excess temperature safety mechanism will respond and interrupt the welding process This state represented as Stud welder not operative is shown alternately with the current operation mode on the display Stud welder not operative RE 2S E Only when this information is no longer shown on the display is it possible to continue the welding operation e Install the stud welder close to the welding location e Ensure correct connected loads for electrical connections see type plate The stud welder has a four core connecting cable 3 phases protective earth conductor er Please also refer to chapter 3 5 Technical Data Make sure mains socket and welding system are properly grounded e Please observe that additional extension cables cause a voltage drop possibly leading to system disturbances e Ensure sufficient ventilation of the working room when operat
15. trouble immediately on the spot If it is difficult or impossible to eliminate the trouble please contact the SOYER customer service responsible for your area or Heinz Soyer Bolzenschwei technik GmbH DANGER Always disconnect the mains cable from the socket and the shielding gas and compressed air supplies from the connections of the stud welder before starting any repair maintenance or cleaning works CAUTION Electric and electronic components may only be replaced by the SOYER customer service or by trained and appropriately qualified personnel 47 BMH 221 9 1 Malfunctions Error Cause gt Elimination Stud welder cannot be One or several phases have failed switched on gt Check mains supply fuses l There is no arc even Stud is too loose in stud holder though system is ready for gt Press stud holder together or tighten it operation System does not weld no System is not switched on or not connected to mains supply or only poor sparking gt Connect system to mains supply and switch on When switching the system on the LEDs shortly light up Operating mode is set to PRE LIFT GAS gt Set operating mode to OP Welding cable control cable or gas hose are not connected properly or are damaged gt Connect cables properly or check for damage Replace if necessary Connecting plug or socket of stud welder is burnt down gt Have plug or socket replaced by SOYER customer service Bot
16. welding zone will always be stronger than that of the stud or base material The following tests are carried out in general practice Visual inspection eBend test Please also refer to the following standard e DIN EN ISO 14555 Arc welding of metallic materials or DVS information sheets e DVS 0902 Drawn arc stud welding e DVS 0904 Practical information Arc stud welding 7 2 Demands on the company The company must employ a technical supervisor responsible for welding matters as well as qualified operating personnel for stud welding 7 3 Test execution 7 3 1 Production of samples The dimensions of the test piece must be sufficient to carry out all tests The thickness of the test piece must be the same as used in later production Use the same welding positions and edge distances as on the component to be welded later If it is possible and sensible from an economical point of view use parts that are identical to those used in later production E Comply with the minimum sheet thickness as per DIN EN ISO 14 555 43 soyer 7 7 3 2 Visual inspection BMH 22i The visual inspection serves as a rough check for major defects The uniformity of the weld is assessed Good weld quality Optimum setting Regular bright and complete collar Poor weld quality e g caused by insufficient welding energy or humid ceramic ferrules Reduced and irregular collar Poor weld quality e g caused by arc blow tilted
17. 1 OP Operating state which must be set for normal welding operation 2 PRE Preweld current test 3 LIFT Lift test 4 GAS Gas test 5 ELECTRODE WELDING 6 TIG WELDING Explanation of displayed parameters e PG program The programs 1 30 are available for the user The welding parameters for the respective welding task can be determined and saved as user program in the programs 1 30 e MC Main current Value set between 300 and 2000 ampere operation mode Stud Welding e MCT Main current time Period of time set between 3 and 1000 milliseconds PCT Preweld current time Period of time set between 40 and 1000 milliseconds e GPT Gas preflow time Period of time set between 0 and 9900 milliseconds during which the shielding gas valve is open before welding and remains open after welding Set 0 when welding without shielding gas e RLT Reload time Period of time set between 0 and 9900 milliseconds during which the blow air valve remains open to allow stud feed from the universal feeder to the welding gun welding head Set 0 to switch off the automatic reload 22 BMH 221 5 1 4 Symbols On Off switch for turning the stud welder on and Electrical energy off i LED lights up when earth terminal of stud welder LED Stud a is connected and stud touches the workpiece on Workpiece T ji LED lights up when pressing release switch of pee REGAS welding gun or welding head valve LED ligh
18. E E EEA 14 Drawn arc welding with shielding GAS cccceecccseeeeeseeeeseeeeeseeeessaeeesaueeeseeeeesaneesaeees 14 Drawn arc welding with ceramic ferrules ccccceecceceeeeeeeeeeeeeeeeeeeeeueeeeeseeeeeeeaeeeeeeas 14 Manual electric welding TIG welding 112ccccceeccccceccccseeccesaueecessnecessueeecesaneeeesaneeeesans 14 Manual electric welding electrode WeICING cccceeccceececaseceeeeeeeceeceseeeesaneeeseeees 15 TES WS a cts cc teers cee cence AAT EIEN see ees selva seen essed ieee E A 15 Construction of the BMH 221 stud weld amp f 11cccccccveeeeceneceeeeecessceeseecessenseecesssnessenes 16 Tenn CA Te shes ote soso cesses soe sae oe oe cee wade seep eee eee 17 4 Installation Of stud welder cccccsessseeeseessseeeeeeesseeeseeenseeeseonenseeeseoeenseeseees 18 5 SIE seacoast E T A N E A detee aed A E A 19 FON ana TEA VOW riranna r EEEE EE A EE Gai 19 Operating ClEMENMS ccccceccccescecceeeeceeeeeceeeeeceaeeeceaceesecesseeesseeeessseesseeesegeessaneeses 21 Display CLIC inire A iaae AEA EAE Eaa RAER 21 LEDAS NY er E E A A scene daeeeiee 21 VDO epe acne ed E E E A E E E EE 23 Freparatlon Tor Star UD oes iinne EEE ete lo AAEE E AAEE EEEE 24 EANN CONNECCION esisi E EEE i 24 Connection of stud welding QUID cccccecccceeececeeeeeceeeeeeeeceseeeceeseeeeseeeeseeeseneeesaeeeees 29 Gas SUDI y aeee A E as en ese eee ode 25 OW SNe SU a setacectc accion otic be siccae ee R E cee
19. ER stud welder e Short cycle drawn arc stud welding without shielding gas and ceramic ferrules e Drawn arc stud welding using ceramic ferrules as auxiliary aid e Drawn arc stud welding using shielding gas as auxiliary aid Manual electric welding electrode welding e TIG welding 13 BMH 221 3 2 Stud welding The PH 5L stud welding gun with control cable and shielding gas equipment is the standard gun to be connected to the BMH 22i stud welder These operating instructions only refer to the BMH 22i stud welder For information regarding the stud welding guns to be used and their setting please refer to the respective operating instructions 3 2 1 Drawn arc welding with shielding gas With this method a gas mixture containing 82 of Argon and 18 of CO 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
20. ET function e g for eliminating troubles or starting the stud welder the first time NOTE The entire data of your working storage are erased when using this function Your personal settings such as welding parameters language selection and other special functions are reset to the basic setting To erase the working storage please proceed as follows e Simultaneously press arrow up arrow down arrow right and arrow left keys and keep them pressed e Turn on off switch to the I position to switch the stud welder on e Follow the instructions on the display Memory cleared Switch off unit nace 5 4 2 Special function Display of operating counter e Simultaneously press arrow up and arrow down keys and keep them pressed e Turn on off switch to the I position to switch the stud welder on e Follow the instructions on the display Operating counter 1234 OK unit off clear arrow right an gt 5 4 3 Special function Selection of language Display of software version number This special function serves to select different languages and to display the version number of the software The languages available are indicated on the display For calling this function please proceed as follows e Simultaneously press arrow up and arrow right keys and keep them pressed e Turn on off switch to the I position to switch the stud welder on and stop pressing the function keys e Follow the instru
21. Operating Instructions BMH 22i Stud Welder soyer p BMH 221 BMH 221 soyer Operating Instructions BMH 22i Stud Welder Serial number BMH 22i stud welder Please enter the serial number here to have it immediately available if you need service support Code designation ee P01345 BMH 22i Standard device mains connection 3 x 400 V POXXXX BMH 22i A Standard device mains connection 3 x 400 V with automatic set for stud reload Heinz Soyer Bolzenschwei technik GmbH Inninger Stra e 14 82237 Worthsee Germany Etterschlag Tel 49 8153 885 0 Fax 49 8153 8030 www soyer de BMH 221 Congratulations on purchasing the BMH 22i SOYER stud welder You have made an excellent choice Your BMH 22i SOYER stud welder was specially developed for the high speed fastening of SOYER welding studs in compliance with DIN EN ISO 13 918 on metallic weldable workpieces Our devices have been tested with regard to safety requirements and corres pond to the currently valid European and national guidelines 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
22. Please pay attention to the following Stud welding technology necessitates that the electrode holder is connected to the negative pole Polarity may however be reversed by changing the plug in connection of the earth and welding cables Two adapter cables are necessary for doing so special accessories Only direct voltage DC operation is available as welding current It is not possible to change over to alternating voltage The current may be adjusted between 80A and 200A in 20A steps 15 BMH 221 Gas and welding current are switched on by pressing the switch of the torch Keep pressing the switch during the welding process Gas and current are switched off when you stop pressing the switch NOTE Do not press the switch of the torch too long There is no optional torch cooling available 3 4 Construction of the BMH 22i stud welder The BMH 22i stud welder has a handy compact and robust design The carrying handles on the top of the housing allow easy transport so that the stud welder can be used at different work places BMH 221 soyer 3 5 Technical data Drawn arc stud welding DS AeA ProceSR Electrode welding rectifier Weianarand SOYER threaded studs DIN EN ISO 13918 from g rang M8 M24 RD MR or 8 22 mm Steel stainless steel and heat resistant steel Power source Inverter technology 300 up to 2000 A stud welding Welding current 80 up to 300 A electrode welding 80 up to 200 A TIG welding
23. R eden de 26 Adjustment Of operation modes 11ccccccsseeseeccssseeeccsssueeecessauuceecessaucueeessaucessesssaunnseesaas 26 Starting the stud welder cc cccccccccceececeeeeecseeeceeeeeceaeeeseaeessecesseeeessaeeesseeeseeessageeees 26 Operation modes parameters cccccceececcesceceececeeeeceeeesaeecseueessuecessaeeesegeeesneesses 26 PE E a A E E EAE E E 30 Special function Erasing the working storage ccccccccseeceeseeeeeeeaeeeeeeaeeeeesaeeeeesaaes 31 Special function Display of Operating counter ce cceecccceeceeeeeeeseeeeseeeeeseeeeseeeeees 31 Special function Selection of language Display of software version number 31 Special function Setting the type of feeder and its functions option 04 32 7 1 7 2 7 3 1 331 7 3 2 13 9 7 3 4 8 1 8 2 8 3 1 8 4 9 1 Appendix A Adjustment of short cycle drawn arc welding guns BMH 221 Special function Setting the feeder operation option ccccccceeeeeeaeeeeeeeeeeseeeeees 33 6 OS Fea LON ree weiss ny inn ent caine amen cae ensue ecumeenenemennowencues 35 Setting welding parameters for standard welding Operation cccccseceeeseeeeeeeeees 35 Welding parameters for welding operation cccseecceeeeeeeeeceeeeeaeeeeeeseeeeeeeaeeeeesaaeees 38 Minimum sheet thickness when welding with drawn arc operation ccsseeeeseeees 38 Welding operation With shiel
24. The LED Final contact indicates the end of the welding process e Do not move the welding gun or welding head during welding Wait until the welding process has been completed before removing the welding gun or head vertically from the welded stud For further information please also refer to the operating instructions of your welding gun or welding head e After completion of the welding process the welding gun or welding head should be held in position for about 5 seconds to allow solidification of the molten metal 6 2 Welding operation with shielding gas The measures mentioned in the Start up of stud welder chapter have already been performed NOTE The applicable accident prevention and safety regulations must be complied with when operating the stud welder 39 BMH 22 6 2 1 Preparation of gas supply KZ 0016 X Example for gas supply Deviations are possible depending on the manufacturer 1 Gas cylinder 5 Shut off valve 2 Hand wheel left open right closed 6 Gas supply hose 3 Manometer for indicating the gas cylinder s 7 Control cock for gas flow rate pressure Screwing in increases the flow 4 Flow meter Screwing out decreases the flow e Connect gas supply hose and gas hose of pressure reducing valve pressure reducing valve not included in delivery to the stud welder e Open hand wheel item 2 of gas cylinder e Open shut off valve item 5 e Use control cock item 7 to set shielding gas
25. The carrying handles are intended for transport by hand only Never pull ropes through these handles 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 handles could rip and the system would fall on the ground NOTE Prevent unauthorized use of the stud welding system by children and unqualified personnel After long system standstill we recommend having the stud welding system checked by SOYER customer servicemen prior to start up The housing of the BMH 22i stud welder corresponds to safety class IP 21 Please observe that this system of protection is not suitable for being operated or transported in the rain 11 Terms of warranty We warrant for this equipment for a period of 12 months in the case of commercial professional or equivalent use When repairs are necessary we guarantee to undertake them in our factory in Etterschlag Parts subject to wear and tear are excluded Any claim to a warranty will be forfeited if damage is caused by improper operation or if repairs or interferences have been made by unauthorized personnel or whenever accessories and spare parts have been used which do not match our equipment We cannot guarantee the perfect function of the stud welder and the quality of welded joints if welding studs acquired from another company are used 51 BMH 22i 12 List of standards and guidelines
26. ay result in a considerable reduction of the rated welding current In addition make sure that the earth clamps are clamped securely to the workpiece and the earth cables as well as the gun cable are securely connected to the stud welder This prevents high transition resistances and arc losses on the clamps or plug in connections which in turn would result in poor welds 24 BMH 221 Examples for various earth connections and possible effects Balanced earth connection Ideal condition The stud is located in the centre of both earth connections Unbalanced earth connection Arc is deflected to the side where there is less current density Additional masses disturb arc symmetry 5 2 2 Connection of stud welding gun e Connect welding cable of welding gun to the welding cable socket and lock it by turning to the right until stop e Insert control cable into control cable connection and tighten with sleeve nut e Please refer to the information given in the operating instructions for the welding guns 5 2 3 Gas supply When welding with shielding gas provide the following connections e Insert gas supply hose s coupler plug of the welding gun into the gas supply socket of the stud welder e Connect the gas hose of the pressure reducing valve pressure reducing valve not included in delivery to the shielding gas connector at the rear side of the stud welder 25 BMH 221 5 2 4 Power supply e Compare the
27. ccccccccesseeeecccesnssseeeeseeccesssasueuseecessssausesseceessssaaaaessesees 10 Dangers in the case of non compliance with safety INStrUCTIONS c11ccccsseeeessneeeenes 10 Before starting to weld cccccccssessccnsssecccsanseccnscseessausecssausesensausecnsausesesacasensanesessanaesess 10 Working with the stud welding equipment 1 ccccceeeccccsecececeeesceeseeecesaeeesesneeeessaeeeees 10 Inadmissible operating methods csseccccccsseeseeceesseeeceesssueecessaueeeeessssaeeeeessaeeseeesssaaes 10 SIODOING INE SIU WEIT soriire irr aia EEE TEE EA 10 2 NS A E E E A E E A E A A E E E A 11 The following should be principally observed 1cccccccsseeeeecssnseeecessauseeecessaesesessnneees 11 MONGE PU DOSE aeri aE E E E EEES EE EENE EEEE 11 Marketing and SCIVICC cccccccsseesecccssneeeccsnauuseecssnaunecessauuceeeessauaueeessaauassessaaeesesssaaasees 11 Information on the documentation 0 sccccccceccccsesecesseeeceesueeecesaececesseeecssseeeessseeeessaeeeeees 12 Information on operating INSTFUCTIONS ccccceecceeseeeeeceeeceeeueeeeeseeeeeesaeeeeeeaaneeesaaees 12 Conduct in the case of MAIFUNCTIONS ccc eecccceeceececeeseeceeseeeeeaeeceseeeeesaeeeeseeeesaeeenes 12 3 Description of stud welder s sssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn mnnn 13 Drawn arc stud welding technology 111ssccccceeeeccscnneeeeceensuececeessaueeeeessaeesseesssaaeseeessaaaes 13 SW O EEE E E E E E
28. ced by SOYER customer service Stud does not lift neither Height of lift is not correctly set preweld current nor main gt Set height of lift in accordance with the operating instructions of your current arc is generated stud welding gun BMH 22i soyer even though LED Stud on Control of stud welder or welding gun is defective Stud does not lift workpiece lights up even though height of lift is correctly set gt Contact SOYER customer service Stud lifts preweld current Operating mode is set to position PRE is initiated but main current gt Set operating mode to position OP is not ignited Preweld current arc breaks gt Clean or grind workpiece surface Lift is too high gt Set lift in accordance with the operating instructions for your welding gun or welding head Gas pressure is too high gt Set gas pressure to the prescribed value Varying welding results Welding energy not correctly adjusted gt Adjust welding energy Cable connections too loose Transition resistances are generated gt Check all cable connections and earth clamps for tight fit Stud too loose or not fully inserted into stud holder until stop gt Insert stud into stud holder until stop Replace stud holder if necessary Magnetic blowing action Arc is forced into a certain direction gt Alter fixture of earth clamps place iron parts on the edges and or rotate welding gun Height of lif
29. ctions on the display 31 BMH 221 Select language arrow up down OK unit off English V 2 0 a l t Y I KF JAE 5 4 4 Special function Setting the type of feeder and its functions option With automatic operation this special function serves to adapt the control to the feeder parameter 1 4 only with BMK feeder The type of feeder connected can be set by means of parameter 5 To call this special function please proceed as follows e Simultaneously press arrow right and arrow left keys and keep them pressed e Turn on off switch to the I position to switch the stud welder on sdb dike i Piston BIAir Feeder 0 0 UVRABMS ry Y WZ 2534 1 E Display when setting feeder type BMS Ld Lhi gv Piston BlAir Ready Cont Feeder 0 0 roo 700 UVRBMK r Y Display when setting feeder type BMK KE idi 1 2 The parameters Piston Ready Cont and BIAir may be selected in 100 ms steps The parameters may be horizontally selected by using the function keys arrow left and arrow right 32 BMH 221 soyer Explanation of parameters Piston This parameter serves to adjust the post blow time of the stud feed blow air beyond the standard measure when the pushing piston in the welding gun welding head has moved forward to press the stud out of the stud holder A longer time setting is required when welding e g above the head to achieve a trouble free stud reload The post blow t
30. d working clothes such as heavy long sleeve shirt cuffless pants and high boots 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 Moving parts can cause injury Beware of moving parts such as fans Keep hair hands loose clothing and any tools away from the air apertures BMH 221 soyer 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 manual describe the following Safety instructions P aN Danger 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 Warning Caution Potential hazards which could result in minor personal injuries Caution Warning of damage Note 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 Important Safety symbols The following pictographs for warnings bans and decrees are used in this manual h k d Ban for persons with pacemakers Warn
31. ding GAS sssccccsseeccceneseessaeeessaueeesssueeessaeeessanenesssaanenes 39 Preparation of gas supply secscecsoncnssanotencescentencsnaeneeaeanasnesedsapteacdaatantdecebteedanncadsadeugnenededs 40 Instructions for welding with shielding GAS cccceeecceseeseeeeeeeeeeeeeeeeeeseeeeeesaaeeeesaeees 40 Welding operation with ceramic ferrUlS ccccsccccccsseeccssnseeecsneeessaueeessaneeeessaaenessananes 41 Instructions for welding with ceramic fErrUlOS cccscccccssseeeeeeneeccsnneeessaeeessaaeeeessaeeeses 41 7 Quality Control stud welding cccccsssseessseeseeeneeeeeeeeeeeeeseeoeeeesseeeeeeeeeeeeeeeees 43 Ce f2 en E E eT Ce ee E ee eae 43 Demands ON the COMPANY uu sccssssseecccccsssesecceseauseecsssuseecesaueeeeesaaauseeesssaaaeeeessaaaneeessaaaes 43 ToS OKC CU ON oain EE E E AE 43 Producton orsa OS eea A E E ee ones 43 Visualinspecti N iaeiei ria en ee e ce ne aia ia Aea RAE 44 Bod TOS e EE EE E sae naeecaseseeesaeeneees 45 TON IGO ee nee E EE ee eee ae eer 45 8 ucili a UnL soins E O EEE E E 46 IMDOMANEINSTUCHONS vinisissixersntisdastasadiniasensiessi anuiyshuniedestinesVncshsadnedebiela ihewivessiaeanerneis 46 Important instructions fOr All service WOFKS sscccccseeeccsaseeecesuesecssneessaeeeessaaeeeessaeanenes 46 RV AUNT ttre cide sects asain tiene sistance naan E E ean apne adie T S 46 Detergents for cleaning the housing ccccccccccssseeeccsseeeceeeseecceeseessaseeeesegseesesaeeeeees 46 Re
32. elded 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 BMH 22i 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 Manual electric welding electrode welding and TIG welding are also possible to a limited extent 2 3 Marketing and service If you have any questions regarding the operation of the BMH 22i stud welder retrofits for special applications or if you require service please contact your responsible service office or the following address Heinz Soyer Bolzenschweiktechnik GmbH Etterschlag Inninger Stra e 14 D 82237 Worthsee Telephone 49 8153 885 0 Telefax 49 8153 8030 www soyer de info soyer de 11 BMH 221 2 4 Information on the documentation The following operating instructions are supplied with the BMH 22i stud welder e Operating instructions for BMH 22i stud welder Order no P00233 2 4 1 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 BolzenschweiBtechnik GmbH result from the respective contract of purchase which als
33. eters for your welding task For doing so please refer to the standard values indicated in the table Welding parameters 6 1 1 1 PG program Press function key arrow right to set the welding program identification character PG PG is represented blinking in the display MODE IPG MC MCT PCT GPT ALT OP 1 300 3 40 0 0 T E 1 or 2 3 or q An upward setting of the welding programs 1 30 is possible when pressing function key arrow up A downward setting of the welding programs 1 30 is possible when pressing function key arrow down 6 1 1 2 MC main current in ampere e Select function MC by pressing either function key arrow left 3 or arrow right 4 e Select the corresponding value for the main current from 300 to 1000 ampere in 20 A steps by pressing function key arrow up 1 or arrow down 2 MODE PG MC MCT PCT GPT ALT OP 1 300 3 40 o 0 ERE 1 or 2 3 or 4 35 BMH 221 The setting values for the most important stud dimensions are represented in tabular form on the front panel of the stud welder 6 1 1 3 MCT main current time in milliseconds e Select function MCT by pressing either function key arrow left 3 or arrow right 4 e Select the corresponding value for the main current time from 3 1000 ms in 1 ms steps by pressing function key arrow up 1 or arrow down 2 MODE PG MC MCT PCT GPT ALT oP 1 300 3 40 0 0 Wi gt ior2 Jorda The
34. ger Drop time mS 1 or 2 3 or 4 KZ 2008 E e Insert a stud into the gun or welding head e Check the immersion depth of the stud and or set it according to the operating instructions of the welding gun or welding head CAUTION Ensure once again that the operation mode is set to LIFT and comply with the safety instructions e Position gun or welding head on workpiece The LED Stud on workpiece lights up moe ao Bo EXT KZ 0024 amp e Actuate the trigger of the gun or the welding head or give a triggering signal via the CNC interface The stud is lifted off the workpiece as long as the triggering signal is there After a maximum of 4 seconds however the lift test will be interrupted to protect the magnet There is no welding current during this period of time o H e wung KZ 2043 X If necessary check and correct the height of lift according to the prescribed standard values for the welding gun or welding head please refer to the table for welding parameters in chapter 6 1 2 If the lift test is carried out on a workpiece which is connected to the earth connection of the stud welder the drop time will be shown in milliseconds on the display If the workpiece is not connected to the earth connection no ground appears on the display MODE Test lift with trigger LIFT Drop time no ground Do not activate the release too often in short intervals as this would cause the thermo ee safety mechanism
35. h earth cables are not properly connected or not connected at all or earth clamps are not attached to the workpiece gt Connect earth cables attach earth clamps to the workpiece Welding points and or earth connection points at the workpiece are not blank gt Prepare workpiece and studs accordingly Height of lift and or depth of immersion are not adjusted correctly gt Refer to the operating instructions of the welding gun to set the height of lift and depth of immersion correctly Gas flow rate is set too high i e higher than 5 l min arc is extinguished Set gas flow rate to the maximum value of 4 5 l min Stud is tilted in ceramic ferrule and does not lift gt Ensure gun is vertically positioned on workpiece Centre ceramic ferrule and stud holder Control of stud welder or welding gun is defective gt Contact SOYER customer service Stud thread scorched Stud holder worn gt Replace stud holder No shielding gas flow Gas cylinder is not or not properly connected to the system and or valve during welding process or shut off valve are not open gt Connect gas cylinder and or open valve or shut off valve Time for gas flow duration is set to 0 gt Set gas flow duration to the desired preflow time Gas flow rate is set too low gt Set gas flow rate to 4 5 l min by means of the control cock Solenoid valve in stud welder is soiled or defective gt Deaerate solenoid valve clean it and or have it repla
36. hanges of the welding conditions The setting values must be modified and the test repeated Note Numerous special accessories are optionally available for perfectly testing stud welded joints BP 1 SOYER Bend Testing Device for non destructive stud testing to support quality assurance procedures DMS 1 SOYER Torque Wrench for non destructive stud testing to support quality assurance procedures For further information please contact our parent company or the customer service responsible for your area or visit our website at www soyer de 45 BMH 221 8 Maintenance 8 1 Important instructions The stud welder is constructed in such a way that only a minimum of maintenance is required The interior of the stud welder should however be cleaned by a specialist at regular intervals depending on the environmental conditions at the location of use WARNING It is prohibited to open the stud welder Due to the inverter technology the service personnel are required to meet special requirements Our after sales service has adequately trained personnel suitable service equipment and the means to carry out all necessary works 8 2 Important instructions for all service works DANGER Always disconnect the mains cable from the mains supply before starting any repair maintenance or cleaning works Always disconnect the connecting plug from the mains supply socket before opening the housing of the stud welder Only trained and appropr
37. iately qualified personnel are allowed to carry out works at the electric mains supply and welding system 8 3 Cleaning Cleaning should be carried out once a week depending on how soiled the stud welder is Please pay particular attention to foreign substances in and around the air apertures in the housing 8 3 1 Detergents for cleaning the housing Almost every detergent without corrosive or acidic substances is suitable for cleaning purposes However please observe the manufacturer s specifications on the detergent you intend to use 8 4 Replacement of components Defective components may only be replaced by trained SOYER servicemen Perfect function of your stud welder can only be guaranteed when original SOYER spare parts are used CAUTION Disconnect the mains cable from the mains supply and disconnect the shielding gas and compressed air supplies before replacing any components Electric and electronic components may only be replaced by the SOYER customer service or by trained and appropriately qualified personnel 46 BMH 221 soyer A CAUTION Should it become necessary to replace fuses only use fuses with the prescribed electrical values Oversized fuses could either cause defects on the electrical system or a fire Vw A DANGER Disconnect the mains plug from the mains supply when replacing fuses 9 Troubleshooting The following list of errors their causes and remedies is designed to help you eliminate any
38. ime can be set between 100ms and 2000 ms e Ready only possible with Feeder BMK function in conjunction with a BMK feeder e With UVR 300 feeder This parameter serves to adjust the waiting period of the hexagonal barrel in the feeding position with simultaneous post vibration of studs Depending on the type of feeder a basic setting between 500ms and 1000ms is recommended e With UVR 250 feeder This parameter serves to adjust the after run period of the feeder when the light barrier has detected a stud in the stud escapement e Cont only possible with Feeder BMK function in conjunction with a BMK feeder This parameter serves to adjust the post vibration period of the feeder to fill the outlet rail when a stud has been brought in blow off position Depending on the type of stud a basic setting between 500ms and 1000ms is recommended e BIAir This parameter serves to adjust the delay time of the stud feed blow air after the injection piston in the welding gun welding head has moved back After the set delay time the stud feed blow air is activated This is necessary e g in the case of a short stud feed hose The delay time can be set between 100ms and 2000ms e Feeder RUT This parameter serves to adjust the feeder type connected UVRBMS and UVRBMK can be set as feeder types 5 4 5 Special function Setting the feeder operation option This special function serves as a help for setting the feeder operation when the st
39. ing of a danger spot General ban only in combination with an additional safety e Ban only in combination with an additional safety symbol Warning of dangerous electric voltage Warning of inflammable substances Protect required Do not touch Housing is current carrying Warning of electromagnetic field Warning of explosive substances Ear protection required General instructions are marked with the hand symbol Fire extinguisher Warning of moving parts A Protective gloves required BMH 221 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 have to be exactly regulated by the user If your personnel do not have the necessary knowledge they have to be trained and instructed If necessary this can be done by the supplier on behalf of the user Furthermore the user must ensure that the contents of the operating instructions are fully understood by the staff The society of welding institutes GSI Gesellschaft der Schweif technischen 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
40. ing studs types PD MD RD UD and SD similar to DIN EN ISO 13 918 6 3 1 Instructions for welding with ceramic ferrules e Start the stud welder as described in chapter 5 e Only use ceramic ferrules which are absolutely dry and do not show any flaws e Only use ceramic ferrules which match the type and size of the studs e Start by carrying out test welds in order to achieve optimum welding results If necessary modify the prescribed welding parameters e Insert stud into stud holder until stop e Make sure stud is centred in the ceramic ferrule holder 41 BMH 221 e Place ceramic ferrule on ceramic ferrule holder e Position the welding gun in such a way that the centre of the stud points exactly toward the marked welding point e Make sure that the gun does not tilt i e that the ceramic ferrule is positioned evenly on the workpiece e Start welding process The LED Final contact lights up after completion e After completion of the welding process the welding gun or welding head should be held in position for about 5 seconds to allow solidification of the molten metal e Remove gun vertically to prevent widening and damaging of the stud holder e Knock off ceramic ferrule from the welded area 42 BMH 221 soyer 7 Quality control stud welding 7 1 General Provided that the SOYER stud welding system is properly used and the materials are appropriately selected the strength of the welding joint
41. ing the welding system NOTE The housing of BMH 22i stud welder corresponds to safety class IP 21 Please observe that this system of protection is not suitable for being operated or transported in the rain CAUTION When welding with shielding gas make sure that the gas cylinder is installed safely and vertically in its admissible accident proof installation device It must not be installed in a horizontal position since the gas cylinder connection and or manometer could be easily damaged BMH 221 soyer 5 Start up 5 1 Front and rear view E E E E E E E E ee ites Front view of BMH 22i stud welder Oof GN oN 11 12 e OFF switch to turn the stud welder off e Signal lamp operation mode e ON switch to turn the stud welder on e LCD display e LED displays for function control e Function keys for setting the welding parameters Air function forward option e Air function backward option Connection for welding guns or heads with automatic stud feed e Control cable connection e Welding cable socket The control cable connection and the welding cable socket serve to connect the stud welding guns or heads to the stud welder e Gas connection socket Before welding with shielding gas connect the gas hose of the welding gun or head to the gas connection socket e Earth cable connectors The earth cable connectors serve to connect the earth clamps to the stud welder 19 20 13
42. ins supply BMH 221 5 1 1 Operating elements e On Off switch Turn on off switch to the I position to switch the stud welder on The signal lamp shows that the stud welder is operative Turn on off switch to the O position to switch the stud welder off e Function keys for setting the welding parameters Ds 1 KZ 2006_1 X 6 1 Function key arrow up 6 3 Function key arrow left 6 2 Function key arrow down 6 4 Function key arrow right e Function keys arrow up down Modification of selected parameters flashing symbol in display e Function keys arrow left right Selection of parameters to be modified shifting of the flashing symbol to the left or right 5 1 2 Display elements e LED displays 1 2 3 4 5 6 T 8 HoeBeaeaeoo e K2 2012 1 2 5 1 LED Stud on Workpiece 5 5 LED Main Current 5 2 LED Release 5 6 LED Final Contact 5 3 LED Gas Valve Open 5 7 LED no function 5 4 LED Lift 5 8 LED no function 5 1 3 LED display The first line of the display shows the designation of the parameters to be set The second line shows the set value When the parameter designation is flashing you may change its value by using the keyboard PG MC MCT PCT GPT RLT OP 1 200 J 40 0 Q HE 201 1 E 21 BMH 22 Explanation of displayed operation modes e MODE Operation mode set It is possible to set six different operation modes
43. main current times for the most important stud dimensions are represented in tabular form in chapter 6 1 2 Welding parameters for welding operation 6 1 1 4 PCT preweld current time in milliseconds e Select function PCT by pressing either function key arrow left 3 or arrow right 4 e Select the corresponding value for the preweld current time from 40 1000 ms in 20 ms steps by pressing either function key arrow up 1 or arrow down 2 Ca MODE PG MC MCT P T GPT RLT i OP 1 200 2 40 0 0 Oe gt 1or 2 2 or 4 6 1 1 5 GPT Gas preflow time in milliseconds The gas preflow time is the period of time during which the shielding gas valve is open before starting the welding process and remains open after the welding process has been completed Set value 0 when welding without shielding gas e Select function GPT by pressing either function key arrow left 3 or arrow right 4 e Select the corresponding value for the gas preflow time from 0 9900 ms in 100 ms steps by pressing function key arrow up 1 or arrow down 2 36 BMH 221 MODE PG MC MCT pct GPT RLT OP 1 300 3 40 i g TBE i r 2 Jorda 6 1 1 6 RLT reload time in milliseconds The reload time is the period of time the blow air valve requires for transporting the stud from the universal feeder to the welding gun or welding head The longer the blow air hose is the higher you have to set the reload time correspondingly If au
44. o 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 welding equipment 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 2 4 2 Conduct in the case of malfunctions If malfunctions occur first try to detect and eliminate the causes according to the Troubleshooting list in chapter 9 of these 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 e Customer number e Product designation options e Serial number e Year of construction e Stud and workpiece material e Stud dimensions This information will help us both to save time and unnecessary costs e g caused by delivering the wrong spare parts 12 BMH 221 3 Description of stud welder 3 1 Drawn arc stud welding technology HE W 1 E Illustration 1 Drawn arc stud welding technology The BMH 22i SOYER stud welder runs according to the principle of drawn arc stud welding A D C power supply with inverter technology provides the welding current For detailed information please refer to the foll
45. owing regulations e DIN EN ISO 14555 Arc welding of metallic materials e DVS Information Sheet 0902 Drawn arc stud welding 1 When welding the stud is positioned on the workpiece The preweld current is ignited and the stud is lifted off the workpiece 3 The subsequent ignition of the main current creates a molten pool between stud and workpiece 4 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 studs pins 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 BMH 22i stud welder is suitable for operation with shielding gas and ceramic ferrules A D C power supply with inverter technology provides the welding current IMPORTANT INFORMATION Ensure that the surface is electroconductive Grind hot galvanized parts The following welding methods are possible when using the BMH 22i SOY
46. placement Of COMPONEIMNG eisercice Joededen sued oxgadosdannndupesceesesedannedaedsdene 46 9 Tr OUDICS OO UNG arrea AE AEREE AE AE EEES 47 DAC UONE a E E E E E AE 48 10 Transport and storage sssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn mnnn 51 11 Terms oilwarnranty s ssia E 51 12 List of standards and guidelines ccsceeseseeseeeeeeeesseeeeeeeeneeeseeenseeesseoenes 52 Appendix A BMH 221 soyer 1 Safety precautions These safety precautions are for your safety General safety instructions Become trained and read and follow all safety precautions listed below as well as 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 install operate and maintain the equipment Keep away children and juveniles under the age of 16 years from the equipment WARNING It is prohibited to open the stud welder 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 opera
47. t and or depth of immersion are incorrectly set gt Refer to the operating instructions of your welding gun to set the height of lift or depth of immersion correctly You have used low quality studs with inaccurate dimensions or poor surface finish Only use SOYER welding studs as per DIN EN ISO 13 918 Welding time and or gas flow incorrectly set gt Reset welding time and or gas flow Parent metal not suitable for welding gt Use suitable material combinations Single fillet bulging at equal Bulging is caused by magnetic blow effect The arc is forced into a certain direction gt Alter fixture of earth clamps place iron parts on the edges and or rotate welding gun Intensive sparking stud Time too long flange almost molten down gt Readjust time for main current duration according to the table Welding current too high gt Readjust welding current Stud not welded with total Time too short flange surface deficient gt Readjust time for main current duration according to the table weld joint strength Poor earth connection gt Check earth cables and earth clamps for tight fit tighten if necessary Workpiece surface too soiled gt Clean workpiece surface Stud face deformed gt Use new welding studs Stud projection over stud holder incorrectly set gt Set distance between stud holder and stud face to 2 3 mm BMH 221 Welding gun in tilted position gt Ensure that all
48. t the welding current MODE Current Electrode welding 80 Oe gt 2 4 1 oF i HE ai E e Use the function key arrow up or arrow down 1 or 2 to set the desired current intensity 5 3 2 6 Operation mode TIG WELDING In this operation mode the stud welder works as a TIG welding device Gas and welding current flow when pressing the key on the burner e Use the function key arrow up or arrow down 1 or 2 to set operation mode TIG WELDING w Libii r MODE Current EELEE TIG welding 80 BE l HE 2011 2 1 or 2 Use the function key arrow right 4 to set the welding current w k kidd F MODE gt Current TIG welding 80 2 4 1 oF i e Use the function key arrow up or arrow down 1 or 2 to set the desired current intensity 5 4 Special functions With the stud welder BMH 22i you can call additional special functions Start dealing with the special functions when you are familiar with the basic ee functions of the stud welder The stud welder must be turned off when calling special functions In order to call the respective special function you have to press certain function key combinations and keep them pressed when starting the stud welder Turn off the stud welder by means of the on off switch to terminate the special functions 30 BMH 221 soyer After this the stud welder can be restarted 5 4 1 Special function Erasing the working storage This special function serves as RES
49. ted near electronically sensitive life supporting equipment such as in intensive care units in hospitals Persons with pacemakers must neither operate the stud welding equipment nor stay near it while it is running Electric shock can cause death Prevent electric shock by insulating your body from work and ground Stand on dry insulating material such as rubber mats and wear rubber soled shoes Be sure power source is properly connected to the ground system of the power supply Inspect all cables including power cord for damage or bare wiring Immediately replace damaged or worn cables Always ensure the correct supply voltage in accordance with the data plate Never connect the stud welder to a power supply network with incorrect supply voltage Always disconnect the mains cable 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 stud holders guns cables power source as well as your clothes dry BMH 221 Fumes and gases can cause damage to your health Fumes and suspended matters may be generated during welding Beware of fumes detrimental to health particularly when using surface treated materials If possible
50. ted value of open circuit voltage in volt Field 10 Lowest and highest power range Field 11 Symbol for operating time Field 12 Symbol for rated value of welding current Field 13 Symbol for standardized working voltage Field 11b c Value of operating time in Field 12b c Rated value of welding current in ampere Field 13b c Value of standardized working voltage in volt 3 3 1 Manual electric welding electrode welding Electrode welding allows simple welding works with covered electrodes electrode holders are not included in delivery Please pay attention to the following Stud welding technology necessitates that the electrode holder is connected to the negative pole Polarity may however be reversed by changing the plug in connection of the earth and welding cables Two adapter cables are necessary for doing so special accessories The welding current is adjustable from 80A up to 300A in 20A steps The welding current has to be set depending on the electrode diameter and the welding task Approx 40A for each mm diameter of the electrode may serve as a standard value for the current adjustment CAUTION During electrode welding the connecting socket welding cable and the connecting plug earth cable are always live The open circuit voltage has always a direct voltage of approx 85 V 3 3 2 TIG welding TIG welding allows simple welding works using a TIG welding torch welding torch is not included in delivery
51. three gun legs are simultaneously and evenly positioned on the workpiece Lift not correctly set gt Set lift correctly Stud welder switches off Stud lift not correctly set gt Set stud lift in accordance with the operating instructions of the welding gun Switch stud welder on You have removed the welding gun from the workpiece while main current has been flowing gt Switch stud welder on again eee Arc breaks as gas pressure is too high gt Set gas pressure to the prescribed value gt Grind surface area gt Check fuses of mains supply Fuse of stud welder is defective gt Contact customer service es ee LED Stud welder not There is not enough free space around the stud welder operative lights up gt Make space available to eliminate heat accumulation Excessive welding sequence gt Please observe the admissible welding sequence re eee LED Lift test carried out You have activated the lifting magnet too long or too often when testing too long lights up the lift gt Wait until the coil in the welding gun has cooled down 50 BMH 221 soyer 10 Transport and storage The stud welder is robustly designed and has a two piece metal housing with front and rear panel Owing to electronic components it should be ensured however that transport is free from vibrations The BMH 22i stud welder has two carrying handles on its top for easy transport and mobile use within short distances CAUTION
52. tomatic reload is not required set value 0 The reload time can only be used in connection with optional automatic operation feeder connection e Select function RLT by pressing either function key arrow left 3 or arrow right 4 e Select the corresponding value for the reload time from 0 9900 ms in 100 ms steps by either pressing function key arrow up 1 or arrow down 2 E g MODE PG MC MCT pPcT GPT ALT OP 1 300 3 40 0 0 mE gt 1 or 2 3 or q 37 BMH 221 6 1 2 Welding parameters for welding operation NOTE ee The set welding parameters influence the reproducibility and quality of the welding results to a large extent The parameters depend on the size of the studs and the material properties The values indicated in the tables are standard values which are exclusively valid for studs supplied by SOYER They may vary depending on the type of workpiece the workpiece thickness the surface condition of the workpiece and on environmental conditions e g low outdoor temperatures The settings of the welding gun or welding head also influence the welding parameters Random samples should be taken during any production process to ensure constantly good welding results see DIN EN ISO 14 555 Arc welding of metallic materials The welding parameters were determined with the BMH 22i stud welder 6 8 10 12 14 16 19 20 BeBe oe ane ee ef Se Perret aw wo of Pee a oe a Energ
53. ts up with shielding gas valve being open LED lights up with lifting magnet of welding gun LED Lift being activated LED Main current LED lights up when main current is supplied LED lights up after welding with release switch m LED Final contact being pressed LED lights up when stud welder is operated by LED External remote control via the serial interface RS232 not yet in use Function key Arrow Upward alteration of the operation mode and the display Function key Arrow Downward alteration of the operation mode and 4 down the parameters selected represented blinking in the display i key ATON Selection of parameters to be changed relocation of blinking symbol to the left relocation of blinking symbol to the right Jy Aranon a operator omire forward Air function l il t backward Air supply for stud welding gun welding head with automatic operation optional equipment eas SUPPIY Gas supply for welding gun welding head coupler socket KD 1 4 T Marks earth cable connector to be connected with Earth earth cable G Marks control and welding cable sockets to be un l connected with welding gun soyer 23 BMH 221 5 2 Preparation for start up Connect the stud welding gun and earth cables to the stud welder prior to start up 5 2 1 Earth connection e Attach earth cable to earth cable connectors and lock by turning to the right until stop e Attach earth clamps to
54. ud welder is equipped with an optional automatic set For calling this special function please proceed as follows e Simultaneously press arrow down and arrow left keys and keep them pressed pP e Turn on off switch to the I position to switch the stud welder on and stop pressing the function keys Slide off off off F EF yri E a papaa i Display when setting feeder type BMS or 33 BMH 22 slide Ready Full off off off i P l H AALE Display when setting feeder type BMK By using the function keys arrow left or arrow right you can move the slider in the feeder s stud escapement to the left or right end position and thereby check the setting During this process the operating states of possible existing sensors are displayed as on or off For further information please refer to the operating instructions of your universal feeder 34 BMH 221 soyer 6 Operation a NOTE The applicable accident prevention and safety regulations have to be complied with NOD when operating the stud welder 6 1 1 Setting welding parameters for standard welding operation e Turn on off switch to the I position to switch the stud welder on The stud welder carries out a self test After the self test has been carried out successfully the display shows the setting last used MODE PG MC MCT PCT GPT RLT OP 1 30 3 40 0 0 HE 201 1 E e Set the necessary param
55. workpiece Ensure optimum contact with workpiece Owing to the high welding current an unbalanced current distribution may cause a magnet blow effect on the arc i e the arc for welding the stud is asymmetrical This is shown by an irregular course of the weld upset on the side of the stud The welding results are unsatisfactory and not reproducible For this reason you should attach the earth clamps to the workpiece in such a manner that the welding gun is positioned as close as possible to the centre of the connecting route of both earth clamps This guarantees a current distribution around the stud that is balanced to the largest possible extent and satisfactory welding results Difficult areas are welds on the edge of the workpiece or considerable differences in material thickness i e the material thickness varies by a few millimetres or additional material is welded or riveted to the metal This also includes stud welding on profile sections To ensure good welding results carry out several test welds under different conditions For example simply change the position of the earth clamps or turn the welding gun You may determine the symmetry and quality of the arc during the preweld current test and then optimise them by combining earth connection and gun position accordingly Please ensure that the contact areas of the earth clamps are always kept clean and do not oxidize otherwise high transition resistances could occur that m
56. y A Pi en f r p oo no pa feo o far ine B For studs as per DIN EN ISO 13 918 When using stud diameters exceeding 6 mm we recommend the application of shielding gas or ceramic ferrules in order to prevent pore formation and to optimise bulging 6 1 3 Minimum sheet thickness when welding with drawn arc operation Observance of the minimum sheet thickness prevents the plate from being burnt through during the welding process in ampere Protection Drawn arc stud welding with gt 100 ms 3 up to 300 up to 3000 Ad but 1 mm minimum 16mm welding 12mm Capacitor discharge drawn lt 10ms 3 up to up to 3000 intial SG 1 10d but 0 5 mm arc stud welding 10 mm minimum CF ceramic ferrule SG shielding gas NP no weld pool protection 38 BMH 221 Important information for standard welding operation stud welding The measures mentioned in the Start up of stud welder chapter have already been performed NOTE The applicable accident prevention and safety regulations must be complied with when operating the stud welder DANGER Persons with pacemakers must not operate the stud welding equipment They must not stay in the vicinity of the stud welder being operated DANGER Never touch stud or stud holder during the welding process These components are current carrying e Position the welding gun or welding head on the workpiece and actuate the trigger The welding process will be started with the parameters set
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