Soyer BMS-4 ACCU-DUO User manual

Operating Instructions
Stud welding device
BMS-4 ACCU-DUO
DE: English version
Read these operating instructions before starting any work!
Doc.ID: P00225
Date of issue: 05.2022
www.soyer.com

Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik 3
Device numbers
We recommend entering your device numbers here so that they can be
accessed quickly if servicing is required.
Device Type Serial number
Stud welding device BMS-4 ACCU-DUO
Stud welding gun PS-0DV
Operating Instructions
Document no.: P00225, 05-2022, translation of the original German manual
(German: P00125)
All inf ormation contained in this document is the property of Heinz Soyer
Bolzenschweißtechnik GmbH.
Revision status
Document Created / Modified Editor Date
Original Created MS/IS May 01st, 2022

4 Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik
CONTENTS
1General information................................................................................................6
1.1 Validity of the operating ins t ruct i ons ...........................................................................6
1.2 Registered trademarks.............................................................................................6
1.3 Declaration of conformity..........................................................................................6
1.4 Manufacturer..........................................................................................................8
1.5 Instruction, training..................................................................................................8
1.6 Standards and directives..........................................................................................8
2Important safety instructions ..................................................................................9
2.1 Warning signs used.................................................................................................9
2.2 General safety instructions .....................................................................................10
2.3 Safety instructions for the mode of operation.............................................................13
2.4 Personal protective equipment ................................................................................14
2.5 Intended use of the stud welding device BMS-4 ACCU-DUO .......................................15
2.5.1 Incorrect use.....................................................................................................15
2.6 Requirements on the part of the operator..................................................................16
2.6.1 Prerequisites for personnel .................................................................................16
3Important safety instructions for battery operation.................................................17
4Transport.............................................................................................................19
5Storage, shutdown...............................................................................................19
6Disposal ..............................................................................................................19
7Description of the BMS-4 ACCU-DUO stud welding device......................................20
7.1 Working method....................................................................................................21
7.1.1 Product features................................................................................................21
7.1.2 Capacitor discharge stud weld i ng.........................................................................22
7.2 Overview of the controls.........................................................................................23
7.2.1 D isp l ay ing t he op erat i ng st at es ............................................................................24
7.2.2 Indication of the battery charging status on the device display ..................................24
7.3 Charging and inserting the battery ...........................................................................25
7.4 Technical data of the BMS-4 ACCU-DUO stud welding device.....................................29
7.5 Permitted stud welding guns ...................................................................................31
7.6 Cleaning the stud welding device.............................................................................31
8Description of th e PS -0DV stud welding gun ..........................................................32
8.1 Technical data of the PS-0DV stud welding gun.........................................................33
8.2 Cleaning of the welding gun....................................................................................33
9Description of the stud chuck ...............................................................................34
9.1 Installation of the s t ud c huc k ...................................................................................35
9.2 Setting the stud distance........................................................................................36
10 Setup and connection...........................................................................................39
10.1 Requirements for the installation site........................................................................39
10.2 Connection of the stud welding device......................................................................40
10.2.1 Power supply ................................................................................................40
10.2.2 Switching the device on and off........................................................................40
10.3 Connecting the stud welding gun.............................................................................40

Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik 5
10.4 Adjusting the charging voltage on the stud welding device...........................................40
11 Welding operation ................................................................................................42
11.1 Carrying out welding..............................................................................................42
11.2 Notes on checking the quality of the weld..................................................................44
11.2.1 Visual inspection ...........................................................................................44
11.3 Welding defects and their causes ............................................................................45
11.4 Malfunctions with an error message on the welding device..........................................46
12 Maintenance and repair ........................................................................................47
13 Service ................................................................................................................47
14 Warranty conditions.............................................................................................47
15 Spare parts..........................................................................................................48

6 Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik
1 General information
These operating instructions contain important inf ormation and rules f or the operation
of the devices. Keep the operating instructions in a readily accessible location close to
the devices.
The term 'Devices' in the operating instructions refers to the stud welding device BMS-
4 ACCU-DUO and the stud welding gun PS-0DV.
Carefully read the operating instructions and any other documents contained in the
technical documentation. Pay particular attention to the saf ety instructions which are
intended to help you recognise any possible residual risks and prevent hazards.
The drawings and diagrams in these operating instructions are for illustration purposes
and may vary slightly from the actual equipment.
The manuf acturer reserves the right to make technical changes.
1.1 Validity of the operating instructions
These operating instructions apply to the following devices:
Stud welding device BMS-4 ACCU-DUO
Stud welding gun PS-0DV
1.2 Registered trademarks
The following terms in these instructions are used with registered trademarks:
SOYER®: Developments/technologies of Soyer GmbH.
1.3 Declaration of conformity
The devices are designed and constructed in accordance with the generally accepted
codes of p ract ic e.
Please note that significant changes to the device will cause the declaration of
conformity to become void.
Furthermore, the manufacturer's warranty may be rendered invalid.

Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik 7
Declaration of conformity – Stud welding device

8 Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik
1.4 Manufacturer
The manuf acturer of the devices is:
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
82237 Wörthsee
Phone: [phone]
Fax: [phone]
Email: inf [e-mail]
Web: www.soyer.de, www.soyer.com
1.5 Instruction, training
Soyer GmbH offers optional and individual instruction in the operation of the devices.
Moreover, Soyer GmbH offers training for customer-specific use of the devices.
Inf ormation on the scope and costs of instruction and training can be obtained
f rom Soyer GmbH.
1.6 Standards and directives
The f ollowing standards, inter alia, must be observed for carrying out stud welding
work and f or the qualification of personnel:
•DIN EN ISO 14555 Welding - Arc stud welding of metallic materials
•DIN EN ISO 14732 Welding personnel - Qualification testing of welding operators and
weld setters for mechanised and automatic welding of metallic materials
•DIN EN IEC 60974-9 Arc welding equipment - Installation and use
•Technical Bulletin DVS 0904 Instruction for practice - Arc stud welding

Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik 9
2 Important safety instructions
Read the f ollowing chapters caref ully and f ollow the saf ety instructions. If you are
uncertain or if an instruction cannot be followed, please contact the manufacturer.
The devices have been constructed according to the generally accepted codes of
practice and in compliance with, and application of, the recognised safety requirements.
To achieve the greatest possible safety, it is essential that all of the safety instructions
in these operating instructions are heeded and followed.
2.1 Warning signs used
Warning signs are used in this document, depending on the potential danger of the
situation.
Safety and information symbols used in this manual
Imminent danger leading to severe injuries or death.
Potentially dangerous situation that may lead to severe
injuries or death.
Potentially dangerous situation that may lead to minor
injuries.
This notice is also used, without a warning triangle, in
the event of imminent damage to property/material.
Additional note on danger due to electric current. The
additional sign is used in conjunction with a warning
sign.
Additional sign indicating the danger of burns. The
additional sign is used in connection with a warning
sign.
Do not touch the surface or the housing: Risk of electric
shock.
Do not touch or open, danger to unauthorised persons.
Danger to persons with medical implants such as
pacemakers.
The inf ormation sign is not a warning sign. It indicates
important and useful information on the relevant topic.

10 Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik
Safety instructions on the devices
As an additional warning of danger, warning labels may be f ound on the devices.
Warning labels are affixed by the manufacturer and must not be removed. If a warning
label is damaged and thus becomes unrecognisable, a new warning label must be
af f ixed immediately.
Warning labels must be obtained from the manufacturer.
2.2 General safety instructions
Danger from electric current, general information
When working on live components, there is a danger to life from electric current.
•Work on electric or electronic components may only be performed by trained
electrotechnical personnel in accordance with currently applicable
electrotechnical regulations.
•Protective devices must not be manipulated or disabled. Protective devices
include, for example, housing and housing covers, fuses or power switches.
•If protective devices have to be removed f or maintenance work, the device
may only be switched on again when all protective devices are installed and
their f unctionality has b een checked.
•Starting the device with f aulty protective devices is not permitted. Faulty
protective devices must be repaired or replaced immediately. Unintentional
operation by third parties must be prevented.

Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik 11
Danger from electric current during maintenance and repair
When working on live components, there is a danger to life from electric current.
•Work on electric or electronic components must only be carried out by trained
electrotechnical personnel of Soyer Bolzenschweißtechnik.
•Bef ore performing any work on the stud welding device or stud welding gun,
the mains switch of the device must be switched off and the mains plug of
the stud welding device must be disconnected. The battery of battery-
operated devices must be removed.
•If protective devices have to be removed for maintenance work, the device
must only be switched on again when all protective devices are installed and
their f unctionality has b een checked.
Danger from magnetic fields
In the area surrounding the device, strong magnetic fields occur during the welding
process. These may inf luence medical auxiliary aids and can theref ore result in
danger to life.
•Persons with electrical medical aids (such as pacemakers) must keep away
f rom the devices.
•The operating personnel must ensure that persons with medical aids keep
away f rom the devices.
Danger of explosion from an inappropriate installation site in explosive
atmospheres
The device is not designed for use in potentially explosive zones.
•The device must not be installed and operated in potentially explosive
atmospheres.

12 Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik
Risk of burns due to hot surfaces
During the welding process, the workpieces and some parts of the welding gun get
so hot that touching them may cause burns.
•Always use personal protective equipment.
•Bef ore working on hot parts of the device, check that they have cooled down.
•Do not hold the gun in the welding area.
Risk of burns from hot welding spatter
Dangerous welding spatter can occur during the welding process.
•Always use personal protective equipment.
Fire hazard from hot welding spatter
Welding spatter or hot workpieces produced during the welding process can result in
f ire hazard.
•Do not store combustible or highly inflammable materials in the welding area.

Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik 13
2.3 Safety instructions for the mode of operation
Hazards due to incorrect working method
Hazards f or operators and third parties can arise due to an incorrect working method.
•Ensure sufficient stability and a dry installation location for the device.
•Make sure you do not knock over the device or pull it down from its position
with the gun cables.
•Make sure, especially with mobile use, of your own good stability during
welding.
•Do not hold the workpiece in your hands during welding. The workpiece must
be securely fixed during the welding process.
•Never wrap the gun lines around parts of your body (e.g. arm) as electric
f ields can occur.
•If the gun is not positioned properly or the gun settings are incorrect, a flash
can occur during welding. Do not look directly into the flash.
•The gun carries out lif ting movements during the welding process. Do not
hold the gun tight in the area of moving parts.

14 Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik
2.4 Personal protective equipment
It is recommended to wear personal protective equipment when working with the stud
welding device.
Danger due to a lack of or incorrect PPE
During stud welding, there is a risk of burns, especially due to hot welding spatter.
The f ormation of strong electric arcs can also cause a glare hazard.
•Always wear suitable, closed protective clothing.
•Type and extent of the protective equipment depends on the respective
occurrence and intensity of welding spatter, arcs and/or noise. This varies
depending on the basic material, stud material, stud size and required
welding performance.
•Please observe the following instructions for protective equipment.
Recommended personal protection equipment
Protective goggles
During weld ing, welding spatter and a f lash of light
occur. Wear appropriate saf ety goggles with side
protection and a f ilter protector, if necessary.
Protective gloves
During welding, the workpieces and parts of the welding
gun get hot and welding spatter occurs
. Wear
appropriate, non-combustible, heat-resistant p ro tective
gloves.
Protective clothing
Welding spatter occurs during the welding process.
Wear appropriate, non-combustible and, if necessary,
heat-resistant, protective clothing.
Safety shoes
Welding spatter occurs during the welding process.
Wear appropriate, non-combustible, heat-res i s tant
saf ety footwear.
Hearing protection
Depending on the welding device and the welding
application, relatively loud welding noises may occur.
Wear appropriate hearing protection.

Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik 15
2.5 Intended use of the stud welding device BMS-4 ACCU-DUO
The SOYER®BMS-4 ACCU-DUO stud welding device with capacitor discharge allows
two M3 weld studs to be simultaneously welded. It is specifically used for attaching heat
cost allocators and suchlike. A separate earth connection is not necessary due to the
double welding gun.
Depending on the individual requirements, the stud distance of the PS-0DV welding gun
can be variably adjusted from approx. 20 - 60 mm.
The battery operation enables mobile working even without power supply. A charging
device included in the scope of delivery is required to charge the battery.
The stud welding device must be operated within the scope of the technical data.
Not all radiators on the market are suitable for welded installation of heat cost
allocators.
Please ensure that you follow the installation instructions and specifications
of the respective manufacturers of the heat cost allocators and radiators.
2.5.1 Incorrect use
Any use of the device deviating from the intended use is considered improper use.
Improper use, unauthorised modification or manipulation of the device will void the
declaration of conformity and all warranty claims against the manufacturer.
Misuse of the welding gun as a tool, e.g. as a hammer for checking the weld quality, is
not permitted.

16 Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik
2.6 Requirements on the part of the operator
The operator of the device must ensure that the preconditions described in this
operating manual regarding safe operation of the device are met.
These include, f or example, the conditions at the installation location, regulatory
requirements f or a saf e workplace, training of the operating personnel and qualified
personnel in using the device, if applicable, compliance with required maintenance work
as well as monitoring the intended use of the device.
These operating instructions must be stored in the vicinity of the stud welding device.
The operator of the unit must ensure that the unit is only used if all protective devices
are present, active and undamaged.
2.6.1 Prerequisites for personnel
Operating personnel
The persons authorised to operate the device must be f amiliar with the stud welding
device and trained accordingly. They must have read and understood these operating
instructions. Furthermore, they must be able to avert or minimise as far as possible any
residual dangers to themselves and third parties when working on the equipment.
To maintain the qualif ication, safety briefings must be carried out at least once a year.
In the event of malf unction or f or maintenance, specially trained personnel or the
manuf acturer must be called in if necessary.
Operators of stud welding equipment must have technical expertise for operating and
adjusting the devices properly as well as for properly carrying out welds.
If welding personnel have to be qualif ied f or certification of welding, the DIN EN ISO
14555 and DIN EN ISO 14732 standards are to be observed.
Trained electrotechnical personnel
The f ollowing applies as a general rule: Work on live elements may only be performed
by authorised electricians.
This work must be perf ormed in line with the applicable technical rules for
electrotechnical devices.
All devices of Soyer Bolzenschweißtechnik GmbH must only be opened by
Soyer personnel or personnel authorised by Soyer.

Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik 17
3 Important safety instructions for battery operation
These operating instructions describe the operation of a stud welding device which is
operated by a lithium-based high-performance battery.
The battery consists of several connected individual cells.
Due to the very high energy density and the technical design of these batteries, the
batteries must be handled very carefully.
Hazards due to improper battery handling
Improper handling and use of a battery may lead to electric shocks, skin irritations,
chemical burns, fire or explosion.
•For saf e handling and operation, the following instructions and recommen-
dations must be strictly observed.
General safety information
•Do not disassemble, open or shred batteries.
•Store batteries out of the reach of children and unauthorised persons.
•Do not expose batteries to heat or fire. Avoid storage in direct sunlight.
•Do not short-circuit batteries.
•Do not store batteries in a hazardous manner in a box or drawer where they can
short-circuit each other or can be short-circuited by other conductive materials.
•Do not expose batteries to mechanical impact.
•A battery must not be removed from its original packaging until it is to be used.
•If a cell is leaking, do not allow the liquid to come into contact with the skin or get into
the eyes. If contact has occurred, please rinse the af f ected area with plenty of water
and consult a physician.
•Only use chargers which are especially designed for this type of battery.
•Do not use rechargeable batteries, cells or other batteries which are not designed for
the use in combination with the device.
•If the connections of batteries are soiled, clean them using a dry, clean cloth.
•Keep batteries clean and dry at all times.
•Batteries must be charged before use. Always use the proper charging device and
observe the manufacturer’s instructions for correct charging.
•Do not charge batteries for an extended period if they are not to be used.
•Do not charge batteries at temperatures below 0 °C.
•The batteries may only be used in the SOYER®devices for which they are intended.
•If possible, batteries should be removed from devices, if the devices are not in use for
several weeks.
•Never use or store batteries and devices with inserted battery in an explosive
environment or in an environment with highly flammable substances.
•Ambient temperature during operation of the device: -20 °C to +50 °C.

18 Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik
Maintenance
•Regularly check whether the battery is in clean and dry condition.
•Use a clean and dry cloth to remove dirt.
Safe storage
•Always store batteries in a clean and dry place. Ideally store them at room temperature
as a maximum or in colder environments (e. g. fridge).
•Admissible temperature during storage: -20 °C to +60 °C (recommended: 0 °C to
+20 °C).
•Do not store batteries in discharged condition. The residual capacity should be at least
50 - 80%.
•Check stored batteries every 2 - 3 months and charge them, if required, to prevent deep
discharge which results in the destruction of the battery.
Handling of defective batteries and disposal
•Always dispose of batteries in an environmentally compatible way in accordance with
applicable local provisions. Consult the local waste disposal company.
•Never dispose of batteries in household waste.
•Do not dispatch batteries. If a battery is defective, please contact Soyer GmbH.
•Do not touch any leaking fluid with bare hands. Collect the fluid and dispose of it in the
correct manner. Wear goggles and protective gloves.
Dealing with battery malfunctions
Abnormal battery performance such as incorrect charging or unusually long charging
times, noticeable sudden power loss, unusual LED messages or leaking f luids can
indicate a battery defect.
•In case of obvious or suspected battery malfunctions, please consult the Soyer
customer service.
Procedure in case of battery fire
•Do not touch the burning battery, not even with protective gloves. A burning battery is
extremely hot due to plasma formation!
•In case of battery fire, remove all flammable objects around the burning battery and call
the f ire brigade if required.
•Ensure suf ficient ventilation to ensure that hazardous and explosive vapours can
escape.
•In case of significant smoke development, please leave the room immediately.
•In case of respiratory tract irritation, consult a physician.
•Fight a battery f ire with water only. Powder extinguishers and fire blankets only serve
to extinguish surrounding fires but are not an effective method to fight the battery fire.

Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik 19
4 Transport
When transporting the device, make sure that it cannot be damaged. Appropriate
packaging can protect the device against weathering effects, especially moisture.
Do not dispatch the battery.
Please observe chapter “3. Important safety instructions for battery operation”
on page 17 ff.
5 Storage, shutdown
During storage or shutdown, make sure to protect the device against dirt and humidity.
Protect the device against unauthorised access by third parties.
For the storage of the battery, please observe chapter “3. Important safety
instructions for battery operation” on page 17 ff.
6 Disposal
Local environmental directives must be observed when disposing of the device.
Water-endangering as well as environmentally hazardous substances must be
disposed of in accordance with legal regulations.
Any material separation must be carried out in accordance with the regulations.
For the disposal of the battery, please observe chapter “3. Important safety
instructions for battery operation” on page 17 ff.

20 Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik
7 Description of the BMS-4 ACCU-DUO stud welding device
The main elements of the stud welding device and its f eatures are described in the
following.
Figure 01: BMS-4 ACCU-DUO stud welding device
Item Designation
a BMS-4 ACCU-DUO stud welding device
b Mains cable for battery charging device
c Battery
d Battery charging device
e Gun cable with PS-0DV stud welding gun