Soyer BMS-4 Akkumat User manual

Operating Instructions
BMS-4 Akkumat
Stud Welder

BMS-4 Akkumat
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BMS-4 Akkumat
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Operating Instructions
BMS-4 Akkumat
Stud Welder
Serial number*
BMS-4 Akkumat Stud Welder
_________________________
Please enter the serial number here to have it immediately
available if you need service support.
Order No.
Code designation
Note
P01135
BMS-4 Akkumat
Standard device
Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 - 82237 Wörthsee - Germany
Tel.: [phone] –Fax: [phone] - www.soyer.de

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Thank you!
Congratulations on purchasing the BMS-4 Akkumat SOYER stud welder.
You have made an excellent choice. Your BMS-4 Akkumat 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.
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 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: April 03, 2006
Revision: ---------------
© Heinz Soyer Bolzenschweißtechnik GmbH 2006 · All rights reserved
Printed in the Federal Republic of Germany

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Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
82237 Wörthsee
CE Declaration of Conformity
We herewith declare that the machine described in the following and the version available on the
market correspond in design and construction to the safety and health requirements of the listed
guidelines and standards. Any unauthorised modification to this machine automatically annuls this
declaration.
Designation of machine : Stud welding device
Machine type : BMS-4 Akkumat
Machine no. : ______________________
Applicable EU directives : RoHS Directive (2011/65/EU)
Low Voltage Directive (2014/35/EU)
EMC Directive (2014/30/EU)
Applied harmonised : EN 60 974-1:2012
standards, in particular EN 60 974-10:2008
Applied national standards : DGUV Regulation 1
Date : 16 July 2015
Producer’s signature : ____________________
Signer’s function : Managing Director

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Table of contents
1Safety precautions................................................................................................................ 8
1.1 Description of reference signs in the operating instructions ................................................ 10
1.2 Staff qualification and training.............................................................................................. 10
1.3 Dangers in the case of non-compliance with safety instructions......................................... 11
1.4 Before starting to weld... ...................................................................................................... 11
1.5 Working with the stud welding equipment............................................................................ 11
1.6 Inadmissible operating methods .......................................................................................... 11
1.7 Stopping the stud welder...................................................................................................... 11
1.8 Utilisation of the rechargeable battery (accumulator) .......................................................... 12
1.8.1 Environment / Disposal.................................................................................................... 12
1.8.2 Maintenance instructions and safety instructions for accumulators ................................ 12
2General................................................................................................................................. 13
2.1 The following should be principally observed... ................................................................... 13
2.2 Intended use ........................................................................................................................ 13
2.3 Marketing and service.......................................................................................................... 13
2.4 Information on the documentation ....................................................................................... 13
2.4.1 Information on operating instructions .............................................................................. 13
2.4.2 Conduct in the case of malfunctions................................................................................ 14
3Description of stud welder................................................................................................. 15
3.1 Description ........................................................................................................................... 15
3.2 Capacitor discharge stud welding technology...................................................................... 15
3.3 Technical data...................................................................................................................... 16
4Installation of stud welder.................................................................................................. 17
5Start-up................................................................................................................................. 18
5.1 Front view............................................................................................................................. 18
5.2 PS-0DV gun ......................................................................................................................... 18
5.2.1 Operating elements ......................................................................................................... 18
5.2.2 Display elements ............................................................................................................. 19
5.3 Preparation for start-up........................................................................................................ 19
5.3.1 Charging the accumulator................................................................................................ 19
5.3.2 Installation of stud holder into stud welding gun.............................................................. 21
5.3.3 Setting the stud distance ................................................................................................. 22
6Operation ............................................................................................................................. 22
6.1.1 Accumulator operation..................................................................................................... 23
7Quality control (stud welding) ........................................................................................... 24
7.1 General................................................................................................................................. 24
8Maintenance......................................................................................................................... 25
8.1 Important instructions........................................................................................................... 25
8.2 Important instructions for all service works.......................................................................... 25
8.3 Cleaning............................................................................................................................... 25
8.3.1 Detergents for cleaning the housing................................................................................ 25
8.4 Replacement of components ............................................................................................... 25
9Troubleshooting.................................................................................................................. 26

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9.1 Malfunctions......................................................................................................................... 27
10 Transport and storage........................................................................................................ 28
11 Terms of warranty............................................................................................................... 28
12 Spare and wear parts.......................................................................................................... 29
13 List of standards and guidelines....................................................................................... 31

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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 operated 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 and wear rubber soled shoes.
Inspect all cables including power cord for damage, wear or bare wiring. Immediately
replace damaged or worn cables.
Always ensure the correct supply voltage in accordance with the data plate. Never
connect the battery charger to a power supply network with incorrect supply voltage.
Always disconnect the battery charger 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.
Fumes and gases can cause damage to your health

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Fumes and suspended matters may be generated during welding. Beware of fumes
detrimental to health, particularly when using surface treated materials. 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.
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 closed working clothes
such as heavy long-sleeve shirts, cuffless pants and safety shoes.
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.

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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
Danger!
Warning!
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.
Caution!
Caution!
Potential hazards which could result in minor personal injuries.
Warning of damage
Note!
Important!
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.
Safety symbols
The following pictographs for warnings, bans and decrees are used in this manual:
Ban for persons with
pacemakers
Ban (only in combination
with an additional safety
symbol)
Do not touch
Housing is current-
carrying
Fire extinguisher
Warning of a danger
spot
Warning of dangerous
electric voltage
Warning of
electromagnetic field
Warning of moving
parts
General ban (only in
combination with an
additional safety
symbol)
Warning of inflammable
substances
Warning of explosive
substances
Eye protection
required
Protective clothing
required
Ear protection
required
Protective gloves
required

General instructions are marked with the hand symbol.
1.2 Staff qualification and training

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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 manufacturer/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 Schweißtechnischen 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 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:
• Failure of important system functions
• Failure of prescribed methods for maintenance
• Danger of persons through electric, mechanic, thermal and acoustic influences
1.4 Before starting to weld...
• Check the state of all cables and cable connections before starting to weld.
• Immediately replace defective cables and cable connections.
1.5 Working with the stud welding equipment
• Comply with all accident prevention regulations which apply to the operation of your welding
device.
If an accident happens,
• switch off the welding device and disconnect it from the mains supply and
• 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
• Press the red OFF button "0"
• If need be, disconnect the mains plug of the external battery charger from the mains socket.
• 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.

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1.8 Utilisation of the rechargeable battery (accumulator)
1.8.1 Environment / Disposal
Batteries and accumulators must not be disposed of with the household waste. Spent batteries and
accumulators must be disposed of in appropriate collection boxes. If there is no collection box nearby,
spent batteries and accumulators can also be handed over to the collection points for problematical
substances provided by the communities.
Accumulators purchased from our company can of course be returned to us after usage.
By doing so, you will fulfil legal regulations (battery ordinance) and contribute to the environmental
protection.
Batteries and accumulators containing harmful substances are marked with the symbol of a
crossed-out garbage bin. Below the garbage bin symbol you will find the chemical marking
of the harmful substances: "Cd" stands for cadmium, "Pb" for lead, "Hg" for mercury.
For further information on the disposal of batteries and accumulators, please refer to
http://www.grs-batterien.de
1.8.2 Maintenance instructions and safety instructions for accumulators
Keep accumulators and battery chargers away from children.
Accumulators must always be charged prior to the first use.
The full capacity of accumulators can only be reached after several charging and discharging cycles.
Accumulators should be fully discharged after approximately 10 charging cycles and then be
recharged again.
Accumulators have a self-discharging effect. If the accumulator has been stored for a longer period of
time, it has to be recharged prior to use.
The optimal room temperature for charging the accumulator is between 15° and 30° Celsius.
Store the accumulator at room temperature and keep it in a dry place.
Keep the charging process always under surveillance. Never leave the accumulator unguarded in the
battery charger as there is the risk of leakage when being overheated!! We do not assume any liability
for consequential damage.
Accumulators must never be burnt, polarised, short-circuited or opened.
Leaking or damaged accumulators may cause chemical burns after contact with skin. Use safety
gloves when handling leaking or damaged accumulators.
Accumulators are consumables (such as batteries) which we do not warrant for.

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2 General
2.1 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, please 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 start-
up. Each operator should confirm this per signature.
• Prevent the stud welder being operated by unauthorized personnel.
• Only trained personnel may operate the stud welder.
• Call a doctor in case of an accident.
2.2 Intended use
The BMS-4 Akkumat capacitor discharge stud welder with battery operation allows two M3 studs
manufactured from steel and stainless steel to be simultaneously welded without earth connection. It
is specifically used for attaching heating costs meters and suchlike.
2.3 Marketing and service
If you have any questions regarding the operation of the BMS-4 Akkumat stud welder, retrofits for
special applications or if you require service, please contact your responsible service office or the
following address:
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
D-82237 Wörthsee
Telephone [phone] Telefax [phone]
www.soyer.de [e-mail]
2.4 Information on the documentation
The following operating instructions are supplied with the BMS-4 Akkumat stud welder:
• Operating instructions for BMS-4 Akkumat stud welder Order no. P00242
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 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.

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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:
• Customer number • Product designation / options
• Serial number • Year of construction
• Stud and workpiece material • Stud dimensions
This information will help us both to save time and unnecessary costs, e.g. caused by delivering the
wrong spare parts.

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3 Description of stud welder
3.1 Description
The BMS-4 Akkumat stud welder allows two M3 studs to be simultaneously welded without earth
connection and is specifically used for attaching heating costs meters and suchlike. It is possible to
variably adjust stud distances. The BMS-4 Akkumat stud welder is suitable for mobile application and
enables you to carry out welding operations without using a mains cable. An external 12 V battery
charger required for charging the battery is included in delivery.
3.2 Capacitor discharge stud welding technology
The BMS-4 Akkumat SOYER stud welder runs according to the principle of capacitor discharge with
tip ignition as defined in DVS Leaflet 0903 (DVS = German Welding Society).
This system uses the sudden discharge of a capacitor battery to generate arc energy.
Stud tip touches workpiece
Ignited arc generates a fusion
zone on stud and workpiece
Stud is plunged into the
welding pool. Material solidifies
and stud is welded
For further information, please refer to www.soyer.de
IMPORTANT INFORMATION
Ensure that the surface is electroconductive.
Grind coated parts.

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3.3 Technical data
Description
BMS-4 Akkumat
Welding process
Capacitor discharge stud welding
Standard gun
PS-0DV double welding gun, stud distance adjustable from 20 - 40
mm
Welding range
2 x M3, steel and stainless steel
Power source
Capacitor 44,000
Charging voltage
Max. 110 volts DC
Welding sequence
2 –3 double welds /min
Battery
12 V / 4.0 Ah
Battery capacity
approximately 150 M3 double welds at 20°C ambient temperature
Power supply
External battery charger 100 –240 volts, 50 –60 Hz
Protection system
IP 21
Dimensions
230 x 95 x 295 mm (w x h x d)
Weight*
7 kg including battery and welding gun
Colour
RAL 5009 azure
Subject to technical changes
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.
* Slight deviations are possible depending on accessories.

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4 Installation of stud welder
• 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.
• Although the stud welder is resistant to environmental influences, it should be protected against
dampness and dust.
• Please pay particular attention to the bearing strength of the workshop furniture and ensure a safe
and stable position of the welding equipment.
• Make sure there is sufficient free space around the air apertures, otherwise the device safety
mechanism will respond and interrupt the welding process.
• Install the stud welder close to the welding location.
• Ensure sufficient ventilation of the working room when operating the welding system.
NOTE
The housing of the 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.
• Ensure correct connected loads for electrical connections as indicated on the type plate
and/or battery charger.

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5 Start-up
5.1 Front view
1 LED displays
3 On/Off switch
2 Gun cable with stud welding
gun
4 Connecting socket for battery
charger
5.2 PS-0DV gun
1 Bellows (stud holder not visible)
3 Gun cable
2 Protective plate
4 Release button
5.2.1 Operating elements
• On/Off switch

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• This switch serves to turn the stud welder on and off.
- Briefly press switch to turn the stud welder on
- Briefly press switch to turn the stud welder off
5.2.2 Display elements
The BMS-4 Akkumat stud welder is equipped with eight LED displays.
1.1 LED "Ready"
1.5 "Failure" –accumulator is dead
1.2 LED "Stud on Workpiece"
1.6 "Accumulator capacity" up to approx. 20%
1.3 LED "Release"
1.7 "Accumulator capacity", approx. 20 -90%
1.4 LED "Supply voltage on"
1.8 "Accumulator capacity", approx. 90-100%
5.3 Preparation for start-up
5.3.1 Charging the accumulator
Instructions for the accumulator used (lead gel battery)
The accumulator is not always completely charged when the stud welder is delivered.
Prior to the first use, the accumulator should be charged for 12 hours.
The accumulator has to be recharged after every discharge. This also applies to partial
discharge.
The accumulator must NEVER be stored in a discharged condition.
A completely discharged accumulator has to be recharged for at least 12 hours.
Charging times of less than twelve hours require the accumulator to be fully charged after
three days at the latest.
Note
Always connect battery charger to the stud welder’s accumulator before connecting it to
the mains supply. Ensure correct polarity as indicated on the front panel.
Please also refer to the instruction manual of the external battery charger.

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Insert connecting plug of the external battery charger into the connecting
socket located at the stud welder’s front panel.
Use mains cable to connect external battery charger to power supply.
Ensure correct connected loads for electrical
connections as indicated on the type plate and/or
battery charger.
The LED "Supply voltage on" lights up when power is supplied via the
external battery charger.
The accumulator is automatically charged. The LED "Supply voltage on"
lights up at the stud welder to check proper operation. The LEDs 1.6 -
1.8 show the state of charge.
The current state is indicated by a light-emitting diode located on the
external battery charger.
Red LED: Charge with maximum charging current
Green LED: Accumulator is fully charged

Please also refer to the instruction manual of the
external battery charger.