Bolt Feeder Operation Manual

Parts Number 11570001

Serial Number BM12-1699/1701
Date 6.12.2017

Seki Kogyo Co.

7-9 Miyauchi 4-choume
Hatukaichi-shi Hiroshima-ken 738-0034
JAPAN
Tel 81-829-39-2211
Fax 81-829-39-2212

1
 Bolt Feeder Manual

Thank you very much for buying a Bolt Feeder by Seki.

We hope you use it for a long time because this high quality machine is made to last.

2
 Table of Contents
UU

○ Safeguards ４～８
○ Structure ９
○ How to assemble
Ⅰ Bolt Feeder Setting １０
Ⅱ Attach L shaped Bar １０
Ⅲ Attach Upper Electrode and Lower Holder １０
Ⅳ Piping １１～１２
Ⅴ Wiring １３～１４
Ⅵ Positioning of the Kicker Rail １４
○ Adjustment
Ⅰ Preparation １５
Ⅱ Adjust Set Air Pressure １５
Ⅲ Adjust Guide Pin １５～１６
Ⅳ Adjust Finger １６～１７
Ⅴ Adjust Bolt LS １８
Ⅵ Adjust Tube Bracket １９
○ Operating Instructions １９
○ Time Chart ２０
○ Troubleshooting Guide
Ⅰ Selector ２１
Ⅱ Bolt Supply Unit ２１～２３
Ⅲ Error output ２４
○ Drawing / Parts List
Ⅰ Bolt Selector ２５～３３
Ⅱ Bolt Supply Unit／Finger ３４～３８
Ⅲ Kicker ３９～４１
Ⅳ Lower Holder Unit／Upper Electrode ４２～４３
Ⅴ Control Panel ４４
Appendix I/O Table
Ladder Chart

3
 Safeguards
UU

Please read all instructions before you attach, adjust, maintain, or use the Bolt Feeder.
Use it properly. The safety caution is leveled as ‘Great Danger’, ‘Danger’, and ‘Caution’
in these instructions.

If you failed to use the equipment properly, you may be

！ Great Danger at great danger and it may cause death or severe injury.

if you failed to use the equipment properly, you may be

！ Danger
at danger and it may cause death and injury.

if you failed to use the equipment properly, it may cause

！ Caution
moderate injury or slight injury. It may also cause
material damage only.

Ⅰ Precautions during installation

！ Never turn on the electrical power, hydraulic/pneumatic power, or the

water supply while performing installation. Otherwise, such unexpected
action could cause electrocution resulting in injury, or in serious cases,
lead to death. Before performing any operation, verify that electrical
power, hydraulic/pneumatic power and the water supply are turned off.

！ To perform a safe installation, heed the following precautions:

・ Never touch electrically charged areas. Otherwise, it could result in
electrocution.
・ Always install the terminal cover.
・ When replacing parts, always verify that the power is turned off.
Otherwise, it could result in electrocution or mis-operation.
・ Verify that power cord connector is securely connected and the ground
wire is grounded and insulated.
・ Do not set the bolt feeder unit next to areas where intense magnetism
occurs. The effects of magnetism could mis-operation or other
problems.

4
 ・ Connect wiring after verifying that the voltage for the welder
pressurization valve and the voltage for the gun pressurization output
on the bolt feeder control is the same. If the wiring is not connected
under the same voltage conditions it could cause problems.
・ To prevent problem such as sudden movement, verify that a signal
from the exterior is not input when the power to the feeder is turned
on or air is supplied.

！ If liquids such as water coolant spray out, it could cause electrical shorting
or deterioration of control devices and unexpended mis-operation.

II Precautions When Performing Adjustment/Maintenance Work

 If injuries or machine damage occur during operations, stop operations
immediately.
 When performing replacement of worn parts and repairing damage to equipment,
always turn off the power and air.

！ To perform correct adjustment and maintenance, heed the following

precautions:
・ Do not touch terminals during energizing. Otherwise, it could cause
electrocution or mis-operation.
・ When performing program changes, forced output, or RUN/STOP
control operations, read the accompanying sequencer manual and
ensure sufficient safety.
・ When supplying air to the welder, do not allow your hands or head to
come near the cylinder moving area. Otherwise, it could result in
unexpected injury.
・ Do not perform modifications or disassembly under your own accord.
Otherwise, it could cause an accident or mis-operation.
・ When supplying air to the bolt feeder, do not allow your hands or head
to come near the cylinder moving area. Otherwise, it could result in
an unexpected injury.
・ When performing operations on areas which are driven by the motor,
always turns off the power. Otherwise, it could result in an
unexpected injury.
・ During recovery, verify that the startup signal from the exterior is not
input.

5
III Precautions on Use
 Air supply
An appropriate amount of air and air pressure is required to operate the bolt
feeder. Heed the following precautions.
・ Verify that the air supply hose is properly fitted and securely tightened.
・ Verify that the bolt supply hose is properly routed and locked in a position
where it is connected safely.

！ ・ Do not place objects between the feeder rod and other apparatus.
Otherwise, it could result in injury or damage to the machinery. Also,
be careful not to contact electrical parts in which electrical current is
flowing.
・ To prevent unexpected injuries, be careful of the following points.
・ Do not place hands or objects near the bolt separator (motor revolving
area, kicker area) or the supply unit.
・ When removing the protection cover or cleaning, verify air and power
are turned off assuredly.

 Use bolts which are suitable to the bolts used for the upper electrical terminal or
lower guide pin. Otherwise, it could cause injury or part damage.
 Do not use unspecified bolts. Otherwise, it could cause problems.

！ To maintain safe operation, the following personnel should not perform

feeder operation.
・ Personnel with psychiatric disorders.
・ Personnel not having full use of hands, feet, eyes and ears.
・ Personnel on medication (including narcotics).
・ Personnel who have consumed alcohol.
・ Personnel fitted with pacemakers.
・ Personnel not wearing protective clothing.
・ Unqualified personnel (without sufficient training in operation of
equipment).
・ Personnel with long hair (hair not banded).
・ Personnel not wearing protective glasses.

6
！ Bolt feeder operators are required to adequately understand the following
points.
・ The contents of this instruction manual shall be understood.
・ The precautionary items shall be understood.
・ The required protective clothing shall be worn.
・ In case of an emergency, contact locations and contact person(s) shall
be made clear.
・ Methods of handing injured persons and locations of first aid
equipment and materials shall be verified.
・ The method for turning off the switch during an emergency and the
method for restarting operation shall be verified.
・ Equipment inspection methods shall be understood.
・ Sufficient knowledge and understanding of feeder operation are
required.
・ To understand feeder operations, sufficient knowledge of resistance
welding is required.

！ To prevent fire and explosions, heed the following points. (Spatter and
weld matter occurring during welding can cause fires).
・ Do not perform operations near combustible gas or flammable objects.
・ An electric protective device is not equipped on the bolt feeder
equipment. Installation of overload protection equipment such as a
ground leak breaker is recommended.
・ Do not place products which have just been welded near flammable
objects.
・ Have fire extinguishers put in appropriate places in preparation for
unexpected accidents.

7
！ Use the bolt feeder correctly and perform welding work safely.
・ To protect your eyes from spatter and welding matter occurring during
welding, wear protective glasses.
・ Wear protective clothing such as protective gloves, long-sleeved
clothing and a leather apron.
・ Install a protective curtain around the work area to prevent spatter
and welding matter from dispersing.
・ Use ear protection in the event of loud noise.
・ If signals such as the snap switch are input without informing
operators during operations, it could cause an accident or breakdown.
・ Do not place hands or objects around the fingers or electrical terminals
during startup.
・ Always install grounding.
・ Turn off the power when opening the control panel.

8
 Bolt Supply Tube
Structure

Bolt Supply Unit

Motor

Lower Holder Unit

Controller Board

Hopper
Filter＋Regulator

Selector Valve

UU

Kicker

9
How to install
Check the following items before installation.
① All switches (welding, controller, power) are turned off.
② The air pressure source and cooling water source is turned off.
③ The air pressure circuit and cooling water circuit is turned off.

Ⅰ Installation the main body

① Install it on even ground

Bolt Feeder

② Secure the exclusive ground.

Ⅱ L shaped bar assembly
① Drill the hole on the side of the welding machine, then connect the L shaped bar
bracket and the L shaped bar with welding machine.

L shaped Bar Bracket Unit Bracket

L shaped Bar

② Fix the unit bracket to the L-shaped bar.

③ Fix the supply unit assembly to the unit bracket.（Adjust them after all parts are
fixed.）
Ⅲ Lower Holder
After checking the security, put the air into the electrode pressure cylinder of the
welding machine. Do not power on at the same time.
① Install the upper electrode
② Install the lower holder.

10
Ⅳ Piping

Filter Regulater

Pressure Gauge

Air Blow Valve

Rod Valve

B
A
Stopper Valve

B A
Bolt Supply Valve

11
Air Piping

① Connect the bolt supply unit and the rod valve by the air tube.
A port (normal close) cylinder of extract side
B port (normal close) cylinder of retract side
② Kicker, stopper valve, and bolt supply valve have been already connected when
shipping.
③ Connect speed controller attached to lower holder bracket and air blow valve by
the air tube (B port is not used so it’s plugged with hexagonal plug).
④ Connect the tube connector attached to regulator and the tube connector
attached to the lower holder unit by the air tube.
⑤ Connect the air source to the coupler.

Cooling Water Piping

① Connect the cooling water hose to the hose nipple attached to the lower holder.
The direction of IN-OUT does not matter.

hose ni ppl e

tube connector

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Ⅴ Wiring
Check the welding, controller, power switch are turned off.
UCCC

Spot Valve

①
④ Bolt Supply Unit

Welder

②
⑥ ⑤ Kicker

⑦
Welding Timer

Foot Switch

Please refer attached document.(Block Diagram)

13
Ⅵ The positioning of the kicker rail

（ ）

（
）
（

14
 Adjustment
UU

★Before adjustment;
Check installation is properly completed.
Turn the adjustment switch ON.
Spot will be pressurized even when the adjusting switch is ON. Do not set the
foot switch around the bolt feeder.

Ⅰ Preparation
Turn on Welding Power then add Air and Cooling Water.
Check the Power Switch on the Bolt Feeder Controller Board is turned UOFF before
you plug it in.
Set the bolt feeder controller switches as the following drawing.

Power
OFF ON

Bolt Adj ust Rod Test Wel d Parts Feed

Suppl y Onl y &
OFF ON OFF ON Wel d

Ⅱ Setting the Air Pressure

The regulator has been set as the following drawing.

０．４ＭＰａ

０．２ＭＰａ

Ⅲ Adjust the Guide Pin

① Set Guide Pin 1mm above Work surface.

About 1mm

15
 ② Guide Pin can be adjusted by loosening M6 Cap Bolt on Lower Holder Bracket.

M6Cap Bolt

Ⅳ Adjust Finger
Power on and turn the adjust switch ON.
Turn the rod test switch ON and extract the rod of bolt supply unit.
Make sure Finger does not crash into Electrode etc.
① Upper Electrode and Lower Electrode

Adjust Upper Electrode and Lower Electrode so they line up.

② Finger and Lower Electrode

Set the finger as the following drawing when Rod is completely out.

Parall el Parall el
Space about 2-3mm Space about 2-3mm

16
③ Finger and Upper Electrode
Adjust it so the center of Finger and the Upper Electrode are in the same position.

ｂ ａ ＝ｂ

17
 Ⅴ Adjust Bolt LS

Bolt LS

Light comes on while

the work materials and the bolt are
properly pressurelized

①Set Welding Timer to Pressure.

②Turn the adjust switch ON.
③Turn the rod test switch ON.
④Confirm there is one Bolt in Finger.
⑤Set Work and press Spot by pressing Foot Switch leaving Rod out.
⑥Adjust Bolt Insertion Confirmation Switch so LED lamp comes on.
⑦Tighten screw and release pressure.

Ⅵ Adjust Tube Holder

① Do not leave a space between Tube Holder and Finger, so Finger will not be forced
open when Bolt is supplied from Selector.

Set without space

②Put Bolt Supply Hose all the way into the bottom of Tube Holder.

When you operate this issue, make

sure air pressure must be 0.4Mpa.

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 Operating Instructions
UU

ⅠWhen interlocking Bolt Feeder and Welding Machine

① Set switches as the following drawing.

Power
OFF ON

Bolt Adj ust Rod Test Wel d Parts Feed

Suppl y Onl y &
OFF ON OFF ON Wel d

② If there is no bolt in Finger, supply a bolt in by pushing the bolt supply push
button switch.
ⅡWhen activating Welding Machine only
① Set switches as the following drawing.

Power
OFF ON

Bolt Adj ust Rod Test Wel d Parts Feed

Suppl y Onl y &
OFF ON OFF ON Wel d

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U

Troubleshooting Guide
U

Ⅰ Selector
① Motor of Selector does not stop spinning.
Cause： Full Bolt Detecting Proximity Switch is broken.
Measure： Replace the proximity switch.
② Motor of Selector does not spin.
Cause ： Full Bolt Detecting Proximity Switch is not working properly(iron
powder etc. is visible).
Measure： Clean around the switch using Air Blower etc.
③ Bolt got stuck inside of Rail and does not come down.
Cause： Dust or Oil is inside the Rail.
Measure： Clean the Rail using Air Blower etc.

Ⅱ Bolt Supply Unit

① Finger opens when bolt is supplied.
Cause： Air pressure is too high.
Measure： Air pressure is set to 0.4Mpa as usual. If finger opens on this
pressure, reduce the air pressure as far as bolt can be supplied.

Cause： Kick Spring is weakened.

Measure： Replace it.

Cause： There is space between Finger surface and the bottom of Tube Holder.
Measure： Loosen the bolt of the tube holder retracting the rod. Adjust the
bottom of the tube holder lightly touches the finger surface.

Set without space

② Finger remains open.

Cause： Kick Spring is weakened.

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 Measure： Replace it.

Cause： There is a dirt between Arm and Finger.

Measure： Take a bolt from the Finger off and clean Arm and Finger.

Bolt

Ki ck Spri ng

③ Arm remains open.

Cause： Arm Spring is weakened.
Measure： Take Hinge Pin out and pull Arm to replace Arm Spring.

Ar m Spri ng

④ Bolt jumps out of Finger when bolt is supplied.

Cause： The speed of Bolt Supply Unit Cylinder is too fast.
Measure： Adjust the extract speed of the rod by the speed controller.

Cause： Air Blower the side of the Lower Holder Unit is strong.
Measure： Adjust the air by Speed Controller on Lower Holder Bracket.

Cause： The angle of Bolt Supply Unit is not proper.

Measure： Adjust the finger (confirm P.13).

⑤Cylinder switch of lower holder remains on.

Cause： Spatter hinders cylinder from moving up and down.
Measure ： Terminal block (52/53) is output of error. Would you like using
automatic robot?
If you adjust by hand, remove spatter and other dirt after turn off the
switch, and then restart.

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⑥The screw thread of the bolt fails.
Cause： The distance of the tip of guide pin and the bottom of bolt(A) is not proper.
/ or the height of guide pin which has gone out from electrode (B) is not
proper.
Measure 1： Adjust the size as the following drawing.

A
B
2～3mm
5mm

Measure 2： The air pressure to which the guide pin is raised is high.

Here

0. 2Mpa 0. 4Mpa
Adjust as above figure.

Measure 3： Finger is rusted , and it causes not to open left and right properly.

Lublicate here.

Measure 4：The positioning of finger is not accurate.

Refer to Ⅳ Adjust Finger / ② Finger and Lower Electrode on 13 page.

22
 ⑦The point block assembly rotates.
Cause： Rod extract speed is too fast.
Measure： Slow down until the original setting speed.

Ⅲ Error output

All motions are stopped when error is outputted. Turn off the power or short-circuit
the error reset.

Cause of error output ①

Though the solenoid valves of spot dose not start, the lower holder insert check AS
starts.

《Measure》
Checking the lower holder insert check AS, turn off the power or short-circuit the
error reset.

Cause of error output ②

Proximity switch does not start because of the jam of parts or the empty hopper.

《Measure》
Checking the rest of parts in hopper, turn off the power or short-circuit the error
reset.

Checking the jam of parts in hopper, turn off the power or short-circuit the error
reset.

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 Ou
Cf."Selector Assembly".

Ⅰ Selector
Drawing / Parts List

Cf. "M ain Body".

Please inform of the serial number written
on this plate when ordering the parts.

24
Cf. "Air Pressure Equipment".
 BS-2

BS-6

BS-5

25
BS-3

BS-4 BS-1
 BS-8 BS-9
BS-10

BS-11
BS-12
BS-13

BS-14

BS-15

26
BS-7

Main Body
 BS-20

BS-21
BS-22 BS-16
BS-23

BS-18

BS-17

27
BS-24
BS-25 BS-19
BS-26

BS-2

BS-27
BS-28
BS-29
 BS-30

BS-41 BS-42
BS-16 BS-44
BS-31 BS-32
BS-45 BS-48

BS-33 BS-46

28
BS-47

BS-49
BS-50 BS-51

BS-34 BS-40 BS-43

BS-37

BS-35
BS-26
BS-36
BS-39
BS-38
29
BS-54
BS-52
BS-53

BS-55

Selector Assembly
Selector Parts List

Parts Name Type Maker Note

BS-1 Case Seki
BS-2 Plat home Seki
BS-3 Control Base Seki
BS-4 Truss Screw M5 General Parts
BS-5 Vibration Isolation RA15 Kurashiki
Rubber
BS-6 Nut M5 General Parts
BS-7 Panel Seki
BS-8 11Tplane Washer M6 General Parts
BS-9 Washer General Parts
BS-10 Cap Bolt M6*15 General Parts
BS-11 Stainless Hinge General Parts
BS-12 Small Screw M4 General Parts
BS-13 Panel Stop Board Seki
BS-14 Omission Stop Washer TM137-3 Tochigiya
BS-15 Cap Bolt M5 General Parts
BS-16 Cross Cover Seki
BS-17 Motor Bracket Seki
BS-18 Gear Head MX8G18B Panasonic
BS-19 Motor M81X25GV4DG Panasonic
BS-20 Cap Bolt M5*55 General Parts
BS-21 Cap Bolt M6*15 General Parts
BS-22 Washer General Parts
BS-23 11Tplane Washer M6 General Parts
BS-24 Plane Washer M5 General Parts
BS-25 Nut M5 General Parts
BS-26 Hopper Bracket Seki
BS-27 11Tplane Washer M6 General Parts
BS-28 Washer General Parts
BS-29 Cap Bolt M6*15 General Parts
BS-30 Board Cover Seki
BS-31 Hexagon Bolt 11T M6*80 General Parts
BS-32 Plane Washer M5 General Parts
BS-33 Cross Seki
BS-34 Bar Fixation Bolt Seki
BS-35 Magnet φ13 Sagami Neoge Magnet
BS-36 Magnet Holder Seki
BS-37 Cap Bolt M3*5 General Parts
BS-38 Cap Bolt M4*12 General Parts
BS-39 Nut M4 General Parts
BS-40 Stainless Plate Seki
BS-41 Nut M6 General Parts
BS-42 11Tplane Washer M6 General Parts
BS-43 Selecting Board Seki
BS-44 11Tplane Washer M6 General Parts
BS-45 Nut M6 General Parts

30
BS-46 Cap Bolt M6*15 General Parts
BS-47 Washer General Parts
BS-48 Hopper Seki
BS-49 Fall Prevention Plate Seki
BS-50 Rivet General Parts
BS-51 Soundproof Rubber Seki
BS-52 Cap Bolt M6*15 General Parts
BS-53 Washer General Parts
BS-54 11Tplane Washer M6 General Parts
BS-55 Screw General Parts
BS-56 Speed Controller SMC
BS-57 Touch Connector SMC
BS-58 Hexagon Plug 1/8PT General Parts
BS-59 Manifold SS5Y5-41-04-01 SMC
BS-60 Plug Silencer AN203-02 SMC
BS-61 Solenoid Valve SY5140-5LP SMC
BS-62 Filter Regulator AW20-02G-R-A SMC
BS-63 Air Connector SMC
BS-64 Regulator AR20-02G-R-A SMC
BS-65 Nipple General Parts
BS-66 Cap Bolt M4*40 General Parts
BS-67 Spring Washer M4 General Parts
BS-68 Plane Washer General Parts
BS-69 Cap Bolt M6*15 General Parts
BS-70 Spring Washer M6 General Parts
BS-71 Manifold Plate Seki
BS-72 Coupler KK130P-02MS SMC

Notice
1. The space between the Selecting Board and Magnet is already adjusted properly. Do
not loosen the Cross Tightening Bolt.
2. If Magnet and the Selecting Board rub together, and the plating of Magnet Surface
comes off, the magnetic power will be weakened and it will stop selecting bolts.

31
Ⅱ Supply Unit

Cf. ”Tube Holder Assembly”

Cf. ”Cylinder Assembly”

Cf. ”Point Block Assembly”

32
 BU-7
BU-8
BU-9

BU-3

BUS-35

BUS-36

BUS-37

BUS-31B

BUS-2

BU-6
BUS-34
BU-5
BUS-33

BU-4 BUS-1
BUS-32

BUS-31

Tube Holder Assembly

33
 BU-15

BUS-14

BU-17
BU-16

BUS-38
BUS-13B BUS-39

BU-18
BU-12B-D
BUS-11B-D BU-19
BUS-10B

BUS-13

BU-12-D

BUS-11-D
BUS-10

Point Block Assembly

34
 BU-25

BU-26

BU-24
Do not change
the ori gi nal setti ng.

BU-27

BU-23

BU-21

BU-22

BU-20

Clynder Assembly

35
Supply Unit Parts List
Parts Name Type Maker Note
BUS-1 Tube Holder Seki
BUS-2 Tube Holder Bracket Seki
BU-3 Tube Seki Wear-out Parts
BU-4 Cap Bolt General Parts
BU-5 Spring Washer General Parts
BU-6 Plane Washer M4 General Parts
BU-7 Cap Bolt M6 General Parts
BU-8 Washer M6 General Parts
BU-9 Plane Washer M6 General Parts
BUS-10 Bolt(R) General Parts Endurance Parts
BUS-10B Bolt(L) General Parts Endurance Parts
BUS-11-D Finger(R) D type Seki Endurance Parts
BUS-11B-D Finger(L) D type Seki Endurance Parts
BU-12-D Kick Spring(R) D type Seki Wear-out Parts
BU-12B-D Kick Spring(L) D type Seki Wear-out Parts
BUS-13 Arm(R) Seki Endurance Parts
BUS-13B Arm (L) Seki Endurance Parts
BUS-14 Base Seki
BU-15 Hinge Pin General Parts Endurance Parts
BU-16 Cap Bolt M4*12 General Parts
BU-17 Nut M4 General Parts
BU-18 E type Stopper Ring General Parts
BU-19 Arm Spring Seki Wear-out Parts
BU-20 Rod Seki Endurance Parts
BU-21 Cap Bolt M4*12 General Parts
BU-22 Bearing LHFR16 General Parts
BU-23 Cylinder Tube Seki
BU-24 Speed Controller SMC
BU-25 One Touch SMC
BU-26 Cylinder CDM2BZ25-150-DCR98 SMC Endurance Parts
42R
BU-27 Cylinder Switch D-C73 SMC
BUS-31 Finger side board（R） Seki
BUS-31B Finger side board（L） Seki
BUS-32 Cap Bolt M4×12 General Parts
BUS-33 Washer M4 General Parts
BUS-34 Washer M4 General Parts
BUS-35 Cap Bolt M6×12 General Parts
BUS-36 Washer M6 General Parts
BUS-37 Washer M6 General Parts
BUS-38 Nut M4 General Parts
BUS-39 Machine Screw M4×10 General Parts

36
Ⅳ Lower Holder / Upper Electrode

BL-73

BL-74
BL-62

BL-75

BL-61

BL-63

BL-64
BL-66 BL-65

BL-68
BL-70

BL-67

BL-69

BL-71 BE-72

Lower Holder Unit (Cap Tip)

37
Lower Holder Parts List

Parts Name Type Maker Note

BL-61 Lower Holder Seki Endurance Parts
BL-62 Hose Nipple General
Parts
BL-63 Lower Holder Bracket Seki
BL-64 Speed Controller for Air SMC
Blow
BL-65 Guide Pin Seki Wear-out Parts
BL-66 Joint Seki Endurance Parts
BL-67 Resin Rod Seki Endurance Parts
BL-68 Air Cylinder CDM2B20-50Z SMC Endurance Parts
BL-69 Silencer SMC
BL-70 Proximity Switch D-C73 SMC
(confirm bolt insertion
LS)
BL-71 Tube Connector SMC
BE-72 Upper Electrode Seki Wear-out Parts
BL-73 Cap Tip Seki Wear-out Parts
BL-74 KCF Pipe Seki Wear-out Parts
BL-75 Lower Electrode Socket Seki Endurance Parts

38
39