Soyer BMS-6 User manual

Operating Instructions
BMS-6 ISO
Stud Welder

BMS-6 ISO
2

BMS-6 ISO
3
Operating Instructions
BMS-6 ISO
Stud Welder
Serial number*
BMS-6 ISO stud welder _________________________
Please enter the serial number here, so that the data is
immediately available if you need service support.
Heinz Soyer Bolzenschweißtechnik GmbH
Etterschlag
Inninger Straße 14
82237 Wörthsee
Telephone [phone] - 885 - 0
Telefax [phone]
www.soyer.de

BMS-6 ISO
4
We congratulate you on purchasing the BMS-6 ISO SOYER stud welder.
You have made an excellent choice. Your BMS-6 ISO SOYER stud welder was
especially developed for high-speed fastening of insulating nails, cupped head pins and
SOYER welding studs in compliance with DIN EN ISO 13 918 on metallic workpieces .
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 data in this documentation, however, have been verified regularly and necessary
corrections will be incorporated in future impressions. We appreciate any suggestions
for improvement.
Date of issue: April 01, 2002
© Heinz Soyer Bolzenschweißtechnik GmbH 2002 · All rights reserved
Printed in the Federal Republic of Germany

BMS-6 ISO
5
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-6 ISO
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

BMS-6 ISO
6
Table of contents
1General........................................................................................................................................... 9
1.1 The following should be principally observed... ..................................................................... 9
1.2 Application............................................................................................................................ 10
1.3 Information on the product................................................................................................... 10
1.4 Type plate............................................................................................................................. 10
1.5 Information on the documentation ....................................................................................... 10
1.5.1 Chapters of operating instructions................................................................................... 11
1.5.2 Information on operating instructions .............................................................................. 11
1.5.3 Conduct in the case of malfunctions................................................................................ 12
1.6 Contacts and service address.............................................................................................. 12
2Description of stud welder......................................................................................................... 13
2.1 Description of technology..................................................................................................... 13
2.2 Stud welder set-up ............................................................................................................... 13
2.3 View...................................................................................................................................... 14
2.4 Technical data...................................................................................................................... 15
2.5 Circuit diagram of BMS-6 ISO.............................................................................................. 16
2.6 Alteration of mains voltage to 115 / 230 volt........................................................................ 16
3Safety instructions...................................................................................................................... 17
3.1 Description of reference signs in the operating instructions ................................................ 17
3.2 Staff qualification and training.............................................................................................. 17
3.3 Dangers in the case of non-compliance with safety instructions......................................... 18
3.4 Safety-conscious working .................................................................................................... 18
3.5 Safety instructions for the operator/user.............................................................................. 18
3.6 The following should be observed before starting the system… ......................................... 18
3.7 Before starting to weld ... ..................................................................................................... 19
3.8 Safety precautions at installation site................................................................................... 19
3.9 Working with the stud welding equipment............................................................................ 19
3.10 Safety instructions for maintenance, inspection and assembly works................................. 20
3.11 Unauthorized retrofit and spare parts production ................................................................ 20
3.12 Inadmissible operating methods .......................................................................................... 20
3.13 Stopping the stud welder...................................................................................................... 20
3.14 The “S” symbol ..................................................................................................................... 21
4Installation of stud welder ......................................................................................................... 22
5Start-up ........................................................................................................................................ 23
5.1 Total view............................................................................................................................. 23

BMS-6 ISO
7
5.1.1 Operating elements ......................................................................................................... 23
5.1.2 Display elements ............................................................................................................. 24
5.1.3 Connecting elements....................................................................................................... 24
5.1.4 Symbols........................................................................................................................... 24
5.1.5 Fuse elements ................................................................................................................. 24
5.2 Preparation for start-up........................................................................................................ 25
5.2.1 Earth connection.............................................................................................................. 25
5.2.2 Connection of stud welding gun....................................................................................... 25
5.2.3 Mains supply.................................................................................................................... 25
5.3 Operation.............................................................................................................................. 26
5.4 Welding parameters............................................................................................................. 27
6Quality control............................................................................................................................. 28
6.1 General................................................................................................................................. 28
6.2 Demands on the company................................................................................................... 28
6.3 Proof of qualification............................................................................................................. 28
6.4 Type and scope of test......................................................................................................... 28
6.4.1 Standard work test........................................................................................................... 28
6.4.2 Simplified work test.......................................................................................................... 29
6.5 Test execution...................................................................................................................... 29
6.5.1 Production of samples..................................................................................................... 29
6.5.2 Visual inspection.............................................................................................................. 29
6.5.3 Tensile test....................................................................................................................... 29
6.5.4 Bend test.......................................................................................................................... 29
7Maintenance................................................................................................................................ 30
7.1 Stud welder .......................................................................................................................... 30
7.2 Cleaning............................................................................................................................... 30
7.2.1 Detergents ....................................................................................................................... 30
7.3 Replacement of components ............................................................................................... 30
7.4 Fuses.................................................................................................................................... 30
8Spare parts for BMS-6 ISO......................................................................................................... 32
8.1 Spare parts for BMS-6 ISO.................................................................................................. 32
9Troubleshooting.......................................................................................................................... 33
9.1 Error code overview ............................................................................................................. 34
9.2 Troubleshooting ................................................................................................................... 35
10 Transport and storage................................................................................................................ 37
11 Terms of warranty....................................................................................................................... 37
12 Standards and guidelines.......................................................................................................... 38

BMS-6 ISO
8
Appendix A / PS-1 and PS-1K –Capacitor discharge
Adjustment of PS-1 and PS-1K stud welding guns Appendix A
Appendix B / PS-1KI –Capacitor discharge
Adjustment of PS-1KI stud welding gun Appendix B

BMS-6 ISO
9
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, 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 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
MORTAL DANGER
Persons with pacemakers must not operate the stud welding equipment and
must not stay near it while it is running. Ensure that the stud welding
equipment 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, please observe the safety instructions in chapter 3.
• Call a doctor in case of an accident.

BMS-6 ISO
10
1.2 Application
The BMS-6 ISO SOYER ® stud welder with capacitor discharge allows you to
weld SOYER threaded studs, nails and pins with flange in compliance with
DIN EN ISO 13918 and ranging from M3 - M6 or Ø 2 - 5.5 mm made of
coppered steel, stainless steel, brass and aluminium as well as steel cupped
head pins from 2 - 2.7 mm diameter. No auxiliary aids such as shielding gas,
ceramic ferrules or soldering materials are required.
There is usually no reverse marking, discoloration or deformation of the sheet,
so that even thin sheet metals with a thickness of below 1 mm retain their
decorative appearance.
If you need consultation 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
Telephone [phone]
Telefax [phone]
Product designation BMS-6 ISO stud welder
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
• Date of construction
• Production number
• Performance data
• Mains connection values
1.5 Information on the documentation
The following operating instructions are supplied with the BMS-6 ISO stud welder:
• Operating instructions for BMS-6 ISO
Order no.: P00252
For repeat-orders please contact your responsible service office or our parent
company. Please refer to chapter 1.6.

BMS-6 ISO
11
1.5.1 Chapters of operating instructions
The operating instructions describe the start-up and operation of the BMS-6 ISO stud
welder under normal conditions.
The present operating instructions of the BMS-6 ISO stud welder comprise the
following chapters in detail:
• Chapter 1 "General".
Information on application and product, as well as supplementary information.
• Chapter 2 "Description of stud welder". Description of technology.
• 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 "Start-up".
• Chapter 6 "Quality control".
• Chapter 7 "Maintenance". Maintenance measures.
• Chapter 8 "Spare parts"
• Chapter 9 "Troubleshooting”.
• Chapter 10 "Transport and storage".
• Chapter 11 "Terms of warranty".
• Chapter 12 "Standards and guidelines".
1.5.2 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.
WARNING
Do not carry out any actions on the stud welding system 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.

BMS-6 ISO
12
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.
If you require our service, please make sure that you supply us with the following
information:
•Customer number
•Product designation
•Serial number
•Year of construction
•Options
•Material of stud and workpiece
•Stud diameters
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
Telephone [phone]
Telefax [phone]
[email protected]
www.soyer.de

BMS-6 ISO
13
2 Description of stud welder
2.1 Description of technology
BMS-6 ISO SOYER stud welding systems function according to the principle of
capacitor discharge (TS) in compliance with DIN EN ISO 14555 and as defined in
DVS information sheet 0903 (German Welding Society).
This system takes advantage of the sudden discharge of a capacitor battery to
generate electric arc energy.
Stud tip touches
workpiece. Electric arc is
initiated.
Ignited arc generates a
thin fusion zone on stud
and workpiece.
Stud is plunged in molten
pool. Material solidifies
and stud is welded.
The electric arc is initiated via the calibrated and close-fit ignition tip of the welding
studs and welding elements. The stud weld base and the opposite surface of the
workpiece thus start to melt. The stud is then automatically dipped into the thin fusion
zone or into the liquid weld pool. After immediate solidification of the material, an
homogenous 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 gun to be connected to the BMS-6 ISO stud welder is the PS-1 stud
welding gun with control cable and support tube.
Optionally it is possible to connect the PS-1KI stud welding gun for cupped head pins
or the PS-3K, PS-0K, PS-1K contact guns for studs and insulating nails with ignition
tip to the stud welder. These operating instructions only refer to the BMS-6 ISO stud
welder.
For information regarding the stud welding guns required and their adjustment, please
refer to the relevant operating instructions of the stud welding guns.

BMS-6 ISO
14
2.3 View
The BMS-6 ISO stud welder has a handy, compact and robust design. It has a
carrying handle and can be optionally equipped with a shoulder strap.
Illustration: Front view of BMS-6ISO
Dimensions 300 x 120 x 320 mm (w x h x d)
Illustration: Rear view of BMS-6ISO

BMS-6 ISO
15
2.4 Technical data
Designation
BMS-6 ISO
Welding range
SOYER threaded flanged studs, nails and pins as per DIN
EN ISO 13918 from M3 –M6 or 2 –5.5 mm dia, as well as
cupped head pins from 2 –2.7 mm dia and 10 –55 mm in
length
Material
Steel, stainless steel, aluminium and brass
Welding process
Capacitor discharge according to DIN EN ISO 14555 and
DVS information sheet 0903
Standard gun
PS-1 stud welding gun with support tube
Power source
Capacitor battery
Charging capacity
44,000 μF
Charging voltage
50 –200 volt infinitely variable
Welding time
0.001 –0.003 sec
Welding sequence
up to 20 nails or studs / min., depending on stud diameter
Mains supply
115 / 230 Vz shock-proof socket
Operation with 115 V 
reclamping works in the control device
Fuse element
G - fuse link 5 x 20 mm, 2 x 10 A slow, 250 V.
The fuse links are integrated in the cold mounting plug at the
rear side of the stud welder
Weight*
8.4 kg (stud welder without cable)
Colour
RAL 5009 azure blue
Subject to technical changes
*Slight deviations are possible depending on accessories.

BMS-6 ISO
16
2.5 Circuit diagram of BMS-6 ISO
Toroidal mains transformer
+ +
KL8 KL9
KL10
KL11
KL12 KL13 KL14 KL15 KL16 KL17 KL18 KL19 KL20 KL21
KL1 KL2 KL3 KL4 KL5 KL6 KL7
10AT
10AT
PE
N
Mains supply
115/230Vac
50/60Hz
22R
22mF 22mF
3R9
K275
SO105 ISO
26-pole
Front panel PC Board Machine PC Board
L1
I/0
Core 20
5 turns
white
yellow
green
brown
black
brown
yellow / green
red red
blue blue blue
red
white
blue
brown brown
grey
Discharging
resistor
red
red
blue
blue
black
white
yellow
green
# BV973 701.3
Core 25
4 turns
Core 20
5 turns
+ EARTH
+ EARTH
- PISTOL
safety resistor
190V
20V
Cathode
Gate
100W
rt 100W
115V
115V
Flat cable
15-pole socket
1
9
Trigger
Pistol
F1 6.3AT
charging circuit
F2 1A
F3 250mA
control circuit
ventilator
130°C
S30E4A
Charging
module
red
bl bl
1000µF
2200µF
+ +
--
Measuring points
5Vdc 26Vdc
SO115Rev.3
F6 230V
F5 230V
F4 115V
F7 115V
Subject to technical changes
2.6 Alteration of mains voltage to 115 / 230 volt
MORTAL DANGER
Always disconnect the connecting plug from the mains supply socket before opening
the housing of the stud welding equipment. Only trained and appropriately qualified
personnel are allowed to carry out works on the electric power supply and stud welder.
F16.3AT
Steuerplatine SO-115 Rev. 3 (SMD)
Control printedcircuit SO-115Rev. 3
F3 250mA
F2 1AT
F410AT
F710AT
Steuerplatine SO-115 Rev. 3 (SMD)
Control printedcircuit SO-115Rev. 3
F16.3AT
F3 250mA
F2 1AT
F510AT
F610AT
F4 115 V
F7 115 V
F5 230 V
F6 230 V
Netzspannung / Line voltage 115 Volt AC
Sicherung 10AT in Sicherungshalter F4 und F7 einsetzen.
Netzspannung / Line voltage 230 Volt AC
Sicherung 10AT in Sicherungshalter F5 und F6 einsetzen.
setting 115V AC setting 230V AC
Insert fuse 10AT into F4 and F7 fuse holders Insert fuse 10AT into F5 and F6 fuse holders
No. F04538/FA No. F04538/FA

BMS-6 ISO
17
3 Safety instructions
These operating instructions contain basic instructions which have to be complied with
during installation or operation. It is therefore absolutely necessary that these
operating instructions are read by the operator and responsible specialist staff prior to
assembly and start-up. The operating instructions must always be available at the
installation site.
Not only the general “safety instructions” listed under this main item, but also the
special safety instructions e.g. for high temperatures, voltage etc. listed under the
other main items have to be complied with.
3.1 Description of reference signs in the operating instructions
The non-observance of safety instructions can cause damage to persons. The safety
instructions of this manual are marked with the general symbol for danger
safety symbol in compliance with DIN 4844 - W9
Warning of electric voltage is specially marked with the
safety symbol in compliance with DIN 4844 - W8.
In addition to these symbols, the terms "DANGER TO HEALTH" or "MORTAL
DANGER" refer to the degree of a possible danger.
Safety instructions, the non-observance of which may endanger the machine and its
functions, are marked with the words "CAUTION " or "WARNING".
General instructions are marked with the hand symbol

3.2 Staff qualification and training
The staff responsible for operation, maintenance, inspection and assembly must have
the respective qualification for carrying out these works. Field of responsibility,
competence and the supervision of staff has 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.

BMS-6 ISO
18
3.3 Dangers in the case of non-compliance with safety instructions
The non-compliance with safety instructions may not only endanger persons, but also
the welding 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
3.4 Safety-conscious working
The safety instructions listed in this manual, existing national accident prevention
regulations and possible international working, operating and safety regulations of the
user must be complied with.
3.5 Safety instructions for the operator/user
When stud welding, danger may result from
• electric current
• optical radiation
• harmful substances (smoke)
• acoustic shock
• spraying sparks
Your are therefore obliged to restrict dangers to an inevitable degree and to point
these dangers out to the operator and other persons involved.
MORTAL DANGER
Persons with pacemakers must neither operate the stud welder nor stay near it.
3.6 The following should be observed before starting the system…
Before starting up the system, pay attention to the following information:
• Juveniles under the age of 16 years must not operate the stud welding system.
• Read all of the operating instructions before starting the system.
• Only qualified personnel are allowed to operate the system.
• Prevent unauthorized use of the system by children or unqualified personnel.
•.Wear non-combustible closed working clothes.
• Wear a leather apron to protect your clothes from welding spatters that are
generated during the welding process.
• Wear a head protection when carrying out welding works above your head.
MORTAL DANGER
When welding, do not wear clothes soiled with easily combustible substances such as
oil, grease and paraffin oil etc.
• Wear gauntlet gloves made of leather.
• Wear neither rings, watches nor electrically conductive jewellery.

BMS-6 ISO
19
• Wear protective goggles with eye-protecting lens number 2 (DIN 58211, part 6) to
protect your eyes from welding spatters and flashes of light that are generated during
the welding process.
• Wear side-shielded glasses.
• Wear ear protection. Capacitor discharge generates a loud bang.
3.7 Before starting to weld ...
• Check the state of all cables and cable connections before starting to weld.
• Immediately replace defective cables and cable connections.
• Ensure that the air apertures of the housing are not covered. Heat accumulation may
damage the stud welding device.
3.8 Safety precautions at installation site
• When placing the stud welder on tables or similar workshop furniture, ensure that the
system stands firmly and that the table can bear its weight.
• Make sure mains socket and stud welding system are properly earthed.
• Comply with fire prevention regulations and do not weld in hazardous locations.
• Make sure room is well ventilated or extract welding fumes, if necessary.
DANGER TO HEALTH
When welding, fumes and suspended matters may be generated. Beware of fumes
detrimental to health, particularly when using surface-treated materials. If possible,
only weld in rooms which are higher than 3 m. As per VBG 15 special regulations
apply to narrow rooms.
3.9 Working with the stud welding equipment
• Comply with all accident prevention regulations which apply to the operation of your
stud welding device.
One of the accident prevention regulations applicable to stud welders is VGB15
“Welding, cutting and similar working methods”. For more information, please contact
the Employer’s Liability Insurance Association.
MORTAL DANGER
When welding, do not wear clothes soiled with easily combustible substances such as
oil, grease and paraffin oil etc.

BMS-6 ISO
20
MORTAL DANGER
Persons with pacemakers must neither operate the stud welder nor stay near it.
If an accident happens,
• switch off the welding device and disconnect it from the mains supply
• call a doctor.
3.10 Safety instructions for maintenance, inspection and assembly works
Only carry out maintenance works when the welding equipment has been switched off
The user must ensure that all maintenance, inspection and assembly works are only
carried out by authorized and qualified technical personnel.
Generally, only work at the system when it has been switched off and after having
disconnected it from the mains supply. The safety instructions described in the
operating instructions have to be complied with.
Immediately after having completed your work, re-install and activate all safety and
protective devices.
3.11 Unauthorized retrofit and spare parts production
The system may only be retrofitted and modified after consultation with the
manufacturer. Original spare parts and accessories authorized by the manufacturer
guarantee safety. The use of other parts may result in the cancellation of warranty for
any consequences thus caused.
3.12 Inadmissible operating methods
Limit values
Working safety of the stud welding system supplied can only be guaranteed if the
system is used in accordance with its purpose. The limit values indicated in the
chapter “Technical data” must never be exceeded.
3.13 Stopping the stud welder
• Switch off the mains switch (item 7, chapter 5.1) at the rear side of the stud welder
• Disconnect the mains plug from the socket.
• Disconnect
- the control cable (item 4, chapter 5.1)
- the welding cable (item 5, chapter 5.1)
- the earth cable (item 6, chapter 5.1)
from the stud welder.
• Roll up the cables without buckling them.