Soyer BMS-10N User manual

Operating Instructions
Stud Welder
BMS-10N
BMS-10NV
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Serial number*
Stud welder BMS-10N 148-
Serial number*
Stud welder BMS-10NV 148-
* Please mark your type of stud welder with a cross and enter the serial number, so
that these data are available if you need service support.
Heinz Soyer Bolzenschweißtechnik GmbH
Etterschlag
Inninger Straße 14
D-82237 Wörthsee
Phone: ++49-(0) 81 53 / 8 85-0
Fax: ++49-(0) 81 53 / 80 30
E-Mail: [email protected]
[email protected]
Operating Instructions
Stud Welder
BMS-10N
BMS-10NV

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SOYERis a registered trade mark of Heinz Soyer Bolzenschweißtechnik
GmbH.
It is prohibited to transmit or reprint this document, as well as to utilize or disclose its contents, unless this has
been expressly granted.
Non-compliance with this regulation is liable to compensation. All rights reserved, particularly in the case of a
patent grant or 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 data in this documenta-
tion, however, have been verified regularly and necessary corrections will be incorporated in future impressions.
We appreciate any suggestions for improvement.
 Heinz Soyer Bolzenschweißtechnik GmbH 1995 · All rights reserved
Subject to technical changes
Printed in the Federal Republic of Germany
Date of issue: 01.12.1995

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EC Conformity Declaration
in compliance with EC Directive on Machinery 89/392/EEC, appendix IIA
Producer: Heinz Soyer Bolzenschweißtechnik GmbH
Etterschlag
Inninger Straße 14
D-82237 Wörthsee
Declaration: We herewith declare that the machines described in the following and the
versions available on the market correspond in their design and construction to
the fundamental safety and health requirements stipulated by EC Directive on
Machinery. Any modification of this machine without confirmation shall auto-
matically annul this declaration.
Designation of machines: Stud Welders with tip ignition
Machine type: BMS-10N
BMS-10NV
Machine no.: 148-
Applicable EC directives: EC Directive on Machinery (89/392/EEC) in the version 91/368/EEC
EC Directive on Low Voltage (73/23/EEC)
EC Directive on Electromagnetic Compatibility (89/336/EEC)
in the version 93/31 EEC
Applied harmonised EN 292-1 and EN 292-2, EN 60 204-1
standards, in particular: EN 60 974-1
Applied national standards VBG 1, VBG 5,
and technical specifications,
in particular: VDE 0544
Date: January 1, 1995
Producer's signature:
Signer's function: Technical Management

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Contents
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Contents
1 General ___________________________________________________________________________ 1-1
1.1 The following should be principally observed ...____________________________________________1-1
1.2 Application __________________________________________________________________________1-2
1.3 Information on the product _____________________________________________________________ 1-2
1.4 Type plate ___________________________________________________________________________ 1-2
1.5 Information on the documentation_______________________________________________________ 1-3
1.5.1 Chapters of operating instructions_______________________________________________________1-3
1.5.2 Information on operating instructions ____________________________________________________1-4
1.5.3 Conduct in the case of malfunctions _____________________________________________________1-4
1.6 Contacts and service address __________________________________________________________1-4
2 Description of stud welder ________________________________________________________ 2-5
2.1 Tip ignition technology ________________________________________________________________2-5
2.2 Stud welder set-up ___________________________________________________________________2-5
2.3 Dimension ___________________________________________________________________________2-6
2.4 Technical Data _______________________________________________________________________ 2-7
2.5 Block diagram _______________________________________________________________________ 2-8
2.6 Interface ____________________________________________________________________________2-9
2.7 Alteration of supply voltage____________________________________________________________2-10
3 Safety instructions _______________________________________________________________ 3-11
3.1 Description of reference signs in the operating instructions _________________________________3-11
3.2 Staff qualification and training__________________________________________________________3-12
3.3 Dangers in the case of non-compliance with safety instructions _____________________________3-12
3.4 Safety-conscious working_____________________________________________________________3-12
3.5 Safety instructions for the operator/user _________________________________________________3-12
3.6 The following should be observed before starting the system ... _____________________________3-13
3.7 Before starting welding ... _____________________________________________________________3-14
3.8 Safety precautions at installation site____________________________________________________3-14
3.9 Working with the stud welder __________________________________________________________3-14
3.10 Safety instructions for maintenance, inspection and assembly works_________________________3-15
3.11 Unauthorized retrofit and spare parts production _________________________________________3-15
3.12 Inadmissible operating methods _______________________________________________________3-15
3.13 Stopping the stud welder _____________________________________________________________3-15
3.13.1 Stopping the stud welder when welding with normal operation______________________________3-15
3.13.2 Stopping the stud welder when welding with automatic operation ___________________________3-16
3.14 The "S" symbol______________________________________________________________________3-16
4 Installation of stud welder________________________________________________________ 4-17
5 Initiation _________________________________________________________________________ 5-18
5.1 Front and rear view __________________________________________________________________5-18
5.2 General description __________________________________________________________________5-19
5.2.1 Operating elements __________________________________________________________________5-20
5.2.2 Display elements ____________________________________________________________________5-20
5.2.3 Connecting elements_________________________________________________________________5-20
5.2.4 Fuse_______________________________________________________________________________5-21
5.2.5 Symbols ___________________________________________________________________________5-22
5.3 Preparation for initiation_______________________________________________________________5-23
5.3.1 Earth connection ____________________________________________________________________5-23
5.3.2 Connection of stud welding pistol ______________________________________________________5-24
5.3.3 Mains supply________________________________________________________________________5-24

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Contents
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5.4 Adjustment of lift ____________________________________________________________________5-24
5.5 Welding parameters__________________________________________________________________5-25
5.6 Material combination _________________________________________________________________5-26
6 Operation ________________________________________________________________________ 6-27
7 Quality control ___________________________________________________________________ 7-28
7.1 General ____________________________________________________________________________7-28
7.2 Demands on the company ____________________________________________________________7-28
7.3 Proof of qualification _________________________________________________________________7-28
7.4 Type and scope of test _______________________________________________________________7-28
7.4.1 Standard work test __________________________________________________________________7-28
7.4.2 Simplified work test __________________________________________________________________7-29
7.5 Test execution ______________________________________________________________________7-29
7.5.1 Production of samples________________________________________________________________7-29
7.5.2 Visual inspection ____________________________________________________________________7-29
7.5.3 Tensile test _________________________________________________________________________7-29
7.5.4 Bend test __________________________________________________________________________7-30
8 Maintenance _____________________________________________________________________ 8-31
8.1 Stud welder ________________________________________________________________________8-31
8.2 Replacement of components __________________________________________________________8-31
9 Troubleshooting__________________________________________________________________ 9-32
10 Transport and storage___________________________________________________________ 10-35
11 List of standards and guidelines_________________________________________________ 11-36
12 Terms of warranty_______________________________________________________________ 12-37
13 Spare parts _____________________________________________________________________ 13-38
13.1 Spare parts list for BMS-10N stud welder - Overview____________________________________ 13-38
13.2 Exploded view of BMS-10N stud welder - Overview_____________________________________ 13-39
13.3 Spare parts list for BMS-10N stud welder - View A______________________________________ 13-40
13.4 Exploded view of BMS-10N stud welder - View A_______________________________________ 13-41
13.5 Spare parts list for BMS-10N stud welder - View B and C ________________________________ 13-42
13.6 Exploded view of BMS-10N stud welder - View B and C _________________________________ 13-43
13.7 Spare parts list for BMS-10N stud welder - View D and E ________________________________ 13-44
13.8 Exploded view of BMS-10N stud welder - View D and E _________________________________ 13-45
13.9 Spare parts list for BMS-10N stud welder - View F ______________________________________ 13-46
13.10 Exploded view of BMS-10N stud welder - View F _______________________________________ 13-47

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Contents
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Appendix A/PS-3 - Tip ignition
1 Adjustment of stud welding pistol _________________________________________________ A-1
1.1 Adjustment of stud holder______________________________________________________________A-1
1.2 Installation of stud holder into stud welding pistol __________________________________________A-2
1.3 Adjustment of spring pressure (does not apply to stud welding pistol PS-3) ____________________A-3
1.4 Lift (stud welding pistol PS-3) ___________________________________________________________A-4
1.4.1 Determining the lift ____________________________________________________________________A-4
1.4.2 Adjusting the lift ______________________________________________________________________A-5
2 Initiation __________________________________________________________________________ A-6
2.1 Total view ___________________________________________________________________________A-6
2.2 Connecting the stud welding pistols to the stud welder _____________________________________A-7
2.3 Operation ___________________________________________________________________________A-7
3 Spare parts _______________________________________________________________________ A-8
3.1 Spare parts list for stud welding pistol PS-3_______________________________________________A-8
3.2 Exploded view of stud welding pistol PS-3________________________________________________A-9

General
1-1
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1 General
1.1 The following should be principally observed ...
With this stud welder you have purchased a product which
•is state-of-the-art technology
•fully complies with the current safety requirements and
•enables successful working.
Before installing the stud welder, always observe the following:
•Store the operating instructions in a place accessible to every operator
•Ensure that the respective operator has read and understood the operating
instructions prior to installation. Each operator should confirm this per
signature.
•Prevent the stud welder being operated by unauthorized personnel
•Only trained personnel may operate the stud welder
ᏘMORTAL DANGER
Persons with pacemakers must not operate the stud welder and must not
stay in the vicinity of the stud welder while it is running.
Ensure that the stud welder is not operated near electronically sensitive life-
supporting equipment, such as in intensive care units in hospitals.
WARNING
Keep sufficient distance from electronic devices. When stud welding, highly
intensive electromagnetic fields are created which may permanently damage
these devices (e.g. television sets).
•Moreover, observe the safety instructions in chapter 3.
•Call a doctor in case of an accident.
ᏘMORTAL DANGER
The S-symbol is the symbol for welding current sources permitted for
operation with increased electric danger. The S-symbol on our stud welders
refers exclusively to the welding current circuit and not to the complete stud
welder.

General
1-2
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1.2 Application
The SOYER®stud welder BMS-10N with tip ignition allows you to weld pins
and threaded studs ranging from M3 - M8 or Ø2 - 8 mm made of steel and
stainless steel and M3 - M8 or Ø2 - 8 mm made of aluminium and brass
(depending on requirements), as well as a great number of various welding
fasteners (see chapter 2.4, Technical Data). It is also possible to weld welding
fasteners made of aluminium and brass.
The stud welder BMS-10NV with a charging capacity of 132,000 µF enables
you to weld steel studs up to M10.
The visual side of the workpiece is spared to a large extent from pressure
marks or deformations, so that even thin sheet metals under 1 mm sheet
thickness retain their decorative appearance.
If you need advice or assistance in solving problems, please contact either our
parent company or our field engineers.
1.3 Information on the product
Manufacturer Heinz Soyer Bolzenschweißtechnik GmbH
Etterschlag
Inninger Straße 14
D-82237 Wörthsee
Phone: ++49-(0) 81 53 / 8 85-0
Fax: ++49-(0) 81 53 / 80 30
E-Mail: [email protected]
[email protected]
Product designation Stud welder BMS-10N
Stud welder BMS-10NV
Country of origin Germany
1.4 Type plate
The type plate is located on the rear side of the stud welder. It contains the
following information:
•Manufacturer's name
•Manufacturer's address
•Country of origin
•Product designation
•Method of welding
•Date of construction
•Production number
•Performance data
•Mains connection values

General
1-3
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1.5 Information on the documentation
The following operating instructions come with the BMS-10N and BMS-10NV
stud welders:
•Operating instructions for stud welder BMS-10N, BMS-10NV
Order no.: P00191
For repeat-orders please contact:
Heinz Soyer Bolzenschweißtechnik GmbH
Etterschlag
Inninger Straße 14
D-82237 Wörthsee
Phone: ++49-(0) 81 53 / 8 85-0
Fax: ++49-(0) 81 53 / 80 30
E-Mail: [email protected]
[email protected]
1.5.1 Chapters of operating instructions
The operating instructions describe the installation and operation of the stud
welder under normal conditions and comprise the following chapters in detail:
•Chapter 1 "General"
Information on application and product, as well as supplementary informa-
tion
•Chapter 2 "Description of stud welder"
Description of tip ignition technology and of the stud welder
•Chapter 3" Safety instructions"
All safety regulations which are relevant with regard to installation and
operation of the stud welding system
•Chapter 4 "Installation of stud welder"
•Chapter 5 "Initiation"
•Chapter 6 "Operation"
•Chapter 7 "Quality control"
•Chapter 8 "Maintenance"
Maintenance measures
•Chapter 9 "Troubleshooting"
Errors, possible causes and remedies
•Chapter 10 "Transport and storage"
•Chapter 11 "List of standards and guidelines"
•Chapter 12 "Terms of warranty"
•Chapter 13 "Spare parts"

General
1-4
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1.5.2 Information on operating instructions
Legal relationship We draw your attention to the fact that the contents of these operating instruc-
tions are neither part of any former or existing arrangement, pledge or legal
relationship nor are designed for modifying the latter. All obligations of Heinz
Soyer Bolzenschweißtechnik GmbH result from the respective contract of
purchase which also comprises the complete and generally valid warranties.
These contractual warranty terms are neither extended nor restricted by the
implementation of these operating instructions.
WARNING
Do not carry out any actions on the stud welder without specifically knowing
the operating instructions or the respective part. Ensure that only qualified
personnel familiar with the operating instructions and the necessary techni-
cal activities (training!) operate the system.
1.5.3 Conduct in the case of malfunctions
If malfunctions occur, first try to detect and eliminate the causes according to
the list in chapter 9 "Troubleshooting" of our operating instructions. In all other
cases, contact our service department.
Important information If you require our service, please make sure that you supply us with the
if service is required following information:
•Customer number
•Product designation
•Serial number
•Year of construction
•Options
•Material of stud and workpiece
•Stud dimensions
This information will help us both to save time and unnecessary costs, e.g.
caused by delivering the wrong spare parts.
1.6 Contacts and service address
If you have any questions regarding the operation of the stud welding system,
retrofits or if you require service, please contact your responsible service office
or the following address:
Heinz Soyer Bolzenschweißtechnik GmbH
Etterschlag
Inninger Straße 14
D-82237 Wörthsee
Phone: ++49-(0) 81 53 / 8 85-0
Fax: ++49-(0) 81 53 / 80 30
E-Mail: [email protected]
[email protected]

2-5
Description of stud welder
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2 Description of stud welder
2.1 Tip ignition technology
The SOYER stud welding systems run according to the principle of capacitor
discharge with tip ignition as defined in DVS Leaflet 0903 (German Welding
Society).
This system uses the abrupt discharge of a capacitor battery to generate
electric arc energy.
The electric arc is initiated via the calibrated and close fit ignition tip on the
welding studs and elements. The stud weld base and the opposite surface of
the workpiece are melted on. The stud is then automatically dipped in the thin
fusion zone or liquid weld pool. After the immediate solidification of the mate-
rial, an homogeneous high-strength joint is produced in an extremely short
welding time of only 1 - 3 milliseconds (0.001 - 0.003 sec.).
2.2 Stud welder set-up
The standard pistol to be connected to the stud welders BMS-10N and BMS-
10NV is the stud welding pistol PS-3 with control cable. The stud welders are
optionally equipped with an automatic module for the connection of the univer-
sal feeder UVR-250S and for fully automatic stud feed. It is necessary to use
the stud welding pistol PS-3A or the welding head SK-5A when welding with
automatic operation.
Optionally it is possible to connect the stud welding pistols PS-1, PS-1K, PS-
OK and PS-3 as well as the welding head SK-5A. These operating instructions
exclusively describe the stud welders BMS-10N and BMS-10NV.
For information regarding the stud welding pistols to be used as well as their
adjustment and the universal vibrator UVR-250S, please refer to the respective
operating instructions of the stud welding pistols or the universal vibrator UVR-
250S.
Adjusting screw Stud holder
Stud
Workpiece
SZ.0001.E

2-6
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Description of stud welder
2.3 Dimension
The stud welders BMS-10N and BMS-10NV have a robust, handy and
compact design and identical dimensions.
SZ.0045.E
0,1 AT 10 AT
HAUPTSCHALTER
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0
Φ
000
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BMS-10N
+-
Heinz Soyer Bolzenschweißtechnik GmbH ·Etterschlag ·Inninger Str. 14 ·82237 Wörthsee ·Tel.: [phone]
Depth 380 mm
400
220

2-7
Description of stud welder
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2.4 Technical data
Designation
Welding range
Welding process
Standard pistol
Current source
Charging capacity
Charging voltage
Welding time
Welding sequence
Power supply
Fuse element at
front panel
Welding cable
Earth cable
Weight *
Colour
Subject to technical changes
BMS-10N
M3 - M8 or Ø2 - 8 mm with
steel and stainless steel,
M3 - M8 or Ø2 - 8 mm
with aluminium and brass,
depending on requirements
Tip ignition as per DVS Leaflet 0903 with gap and
contact welding
Stud welding pistol PS-3
Capacitor battery
88,000 µF
50 - 200 V infinitely variable up/down
0.001 - 0.003 sec.
up to 20 studs/min, depending on stud diameter
220/230 V, 50/60 Hz, 10 AT, +/- 10 %
(special voltage on request)
0.1 AT for main switch
10 AT for control transformer
3 m highly flexible
2 x 3 m highly flexible
19.5 kg
RAL 5009 azure
SZ.0042.E
BMS-10NV
Like stud welder BMS-10N
but steel studs up to M10
132,000 µF
20.5 kg
*Slight deviations are possible depending on accessories (e.g. automatic set)

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Description of stud welder
2.5 Block diagram
SZ.0067.E
Pistol Earth
Automatic module
N: 88mF NV: 132mF
Ventilator
Control board STA 31
Control board STA 41
Mains
transformer
Supply 115/230V
Mains filter
Mains switch
10AT
0.1AT Pistol
control cable
Feeder
CNC Interfaces

2-9
Description of stud welder
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2.6 Interface
SZ.0068.E
Reload
Reloading
Operational sequence:
Ready
SOW
Start
Reloading is triggered when the head is removed from the stud. It is recommended to set a waiting
period of about 500 ms after the stud has been positioned on the workpiece (SOW) and after the
welding has been completed. This ensures a stabilization of the welding head is achieved prior to
the welding and that the welded area can settle down after the welding.
Customer control
1
2
3
4
5
6
7
8
9
Start
Start
SOW
Release
9 pole D-Sub socket terminal strip
Terminology:
Start:
SOW:
Ready:
Reload:
Contact releases the welding process
Stud on workpiece
Is only required when stud welder is operated via a superior control.
Contact is made when stud touches the workpiece (e.g. head in fore position).
Contact is made after the set charging voltage has been reached.
Contact remains closed during the reload time of the stud
(after removal of the head from the welded stud).
BMS Stud welder
CNC interface
+U external
SOW
Ready Charge ready
Reload time
With a store programmable control which has
a transistor output please observe the polarity!
Contact load: max. 24V, 200mA

2-10
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Description of stud welder
2.7 Alteration of supply voltage
SZ.0069.E
Mains supply
Line Mains supply Line
violet violetblackblack
grey
or white
orange
grey
or white
orange
Binding post
Supply 230V Supply 115V