Soyer BMS-8N User manual

EN
Operating
Instructions
Stud welding devices BMS-8N
BMS-8NV
Stud welding guns PS-1 and PS-1K
PS-3K(Stativ)
PS-0K

EN
Device numbers
We recommend to enter the device numbers in the list so that they can be
accessed quickly if servicing is required.
Operating Instructions
Document no.: P00198, 10-2018, translation of the original instructions
(English: P00298)
All information in this document is the property of
Heinz Soyer Bolzenschweißtechnik GmbH.
Device Type Serial number
Stud welding device BMS-8N
BMS-8NV
Stud welding gun PS-1
PS-1K
PS-3K
PS-3K Stativ
PS-0K
Revision status
Document created/amended Editor Date
Original Created DD 2 October 2018

Operating Instructions Soyer Bolzenschweißtechnik 3
CONTENTS
1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1. Validity of the operating instructions 6
1.2. Declarations of conformity 6
1.3. Manufacturer 8
1.4. Instruction, training 8
1.5. Standards and directives 8
2. Important safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1. Warning signs used 9
2.2. General safety instructions 10
2.3. Personal protective equipment 13
2.4. Intended use of the stud welding device 14
2.4.1 Incorrect use 14
2.5. Intended use of the stud welding guns 14
2.5.1 Incorrect use 14
2.6. Operating company prerequisites 15
2.6.1 Prerequisites for personnel 15
3. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4. Storage, shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6. Description of BMS-8N(V) stud welding devices . . . . . . . . . . . . . . . . . . . . . . 17
6.1. Type differentiation 17
6.2. Working method 17
6.2.1 Product features 17
6.2.2 Capacitor discharge stud welding 17
6.3. Overview of the controls 19
6.3.1 Support table stud diameter/charging voltage 21
6.3.2 Displaying the operating states 22
6.4. Technical data on BMS-8N(V) stud welding device 23
6.5. Permitted stud welding guns 24
6.6. Cleaning the stud welding device 25

4 Operating Instructions Soyer Bolzenschweißtechnik
CONTENTS
7. Description of PS-0K stud welding gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1. Technical data for the PS-0K stud welding gun 27
7.2. Cleaning of the stud welding gun 28
8. Description of the PS-1 stud welding gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.1. Technical data for the PS-1 stud welding gun 30
8.2. Cleaning of the stud welding gun 31
9. Description of the PS-1K stud welding gun . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.1. Technical data for the PS-1K stud welding gun 33
9.2. Cleaning of the stud welding gun 34
10. Description of the PS-3K and PS-3K Stativ stud welding guns. . . . . . . . . . 35
10.1. Technical data for the PS-3K (Stativ) stud welding gun 36
10.2. Cleaning of the stud welding gun 37
11. Description of the stud chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.1. Adjusting adjustable stud chucks 38
11.2. Installing the stud chuck (gun without support) 39
11.3. Installing the stud chuck (gun with support) 41
12. Setup and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
12.1. Requirements for the installation location 43
12.2. Connection of the stud welding device and the stud welding guns 44
12.2.1 Mains connection 44
12.2.2 Connecting the earth cable 44
12.2.3 Connecting the stud welding gun 46
13. Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
13.1. Adjusting the charging voltage on the stud welding device 47
13.1.1 Switching the display 48
13.1.2 Adjusting the charging voltage 48
14. Welding operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
14.1. Carrying out welding 49
14.2. Notes on checking the quality of the weld 50
14.2.1 Visual inspection 50

Operating Instructions Soyer Bolzenschweißtechnik 5
CONTENTS
14.3. Switching off the device 52
14.4. Welding defects and their causes 53
14.5. Malfunctions with an error message 54
15. Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
16. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
17. Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

General information
6 Operating Instructions Soyer Bolzenschweißtechnik
1. General information
These operating instructions contain important information and rules for the
operation of the devices. Keep these operating instructions in a readily accessible
location close to the devices.
In these operating instructions, the term “devices” refers to the stud welding
device and the stud welding gun.
Carefully read the operating instructions and any other documents contained in
the technical documentation. Pay particular attention to the safety instructions
which are intended to help you recognise any possible residual risks and prevent
hazards.
The drawings and illustrations in these operating instructions are for illustrative
purposes and may vary slightly from the actual equipment.
The manufacturer reserves the right to make technical changes.
1.1 Validity of the operating instructions
These operating instructions apply to the following devices:
1.2 Declarations of conformity
The devices are designed and constructed in accordance with the general
accepted codes of practice.
Stud welding devices BMS-8N
BMS-8NV
Stud welding guns PS-0K
PS-1K
PS-1
PS-3K
PS-3K Stativ
i
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.

General information
Operating Instructions Soyer Bolzenschweißtechnik 7
Stud welding device
Heinz Soyer Bolzenschweißtechnik
GmbH Inninger Straße 14
82237 Wörthsee
CE - Declaration of
Conformity
We herewith declare that the design of the machine described below as well as in the
version marketed by us meets the safety and health requirements of the stated
guidelines and standards. Any modification of this machine without confirmation shall
automatically annul this declaration.
Designation of the machine
Machine type
Machine no.
Applicable EU guidelines
Harmonised standards
applied, in particular
National regulations applied
Date
Manufacturer - signature
Function of the signatory
Stud welding device
BMS-8N
BMS-8NV
RoHS directive (2011/65/EU) Low-
voltage directive (2014/35/EU) EMC
directive (2014/30/EU)
EN 60974-1:2012
EN 60974-10:2008
DGUV directive 1
16 July 2015
CEO

General information
8 Operating Instructions Soyer Bolzenschweißtechnik
1.3 Manufacturer
The manufacturer of the devices is:
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
82237 Wörthsee
Phone: [phone]
Fax: [phone]
Email: [email protected]
Web: www.soyer.de, www.soyer.com
1.4 Instruction, training
Soyer offers optional and individual instruction in the operation of the devices.
Moreover, Soyer offers training for customer-specific use of the
devices. The tutorial is available at:
https://www.youtube.com/watch?v=u4JXk8Gzsmg
Information on the scope and costs of instruction and training can be obtained
from Soyer GmbH.
1.5 Standards and directives
The following standards, inter alia, must be observed for carrying out stud welding
work and for 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 60974-9 Arc welding equipment - Installation and use
• Technical Bulletin DVS 0903 Capacitor-discharge stud welding with tip ignition
• Technical Bulletin DVS 0904 Instruction for practice - Arc stud welding
i
Also see our video instructions at
www.youtube.com/user/SoyerGmbH.

Important safety instructions
Operating Instructions Soyer Bolzenschweißtechnik 9
2. Important safety instructions
Read the following chapters carefully and follow the safety instructions. Please
contact the manufacturer if you are uncertain or an instruction cannot be followed.
The devices have been constructed in accordance with the generally accepted
codes of practice and established and usual safety requirements were observed
and applied. In order to reach maximum safety, it is absolutely necessary to follow
and observe all safety instructions specified in these operating instructions.
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
This warning sign indicates imminent danger lead-
ing to severe injuries or death.
This warning sign indicates a potentially dangerous
situation that may lead to severe injuries or death.
This warning sign indicates a potentially dangerous
situation that may lead to minor injuries.
Without the warning triangle, this warning sign is
also used in the event of danger of material dam-
age.
Additional sign indicating danger from electric cur-
rent. The additional sign is used in connection with
a warning.
Additional sign indicating the danger of burns. The
additional sign is used in connection with a warn-
ing.
Do not touch the surface or the housing: Shock
hazard.
Do not touch or open, danger to unauthorised per-
sons.
Danger to persons with medical implants such as
pacemakers.
The information sign is not a warning sign. It indi-
cates important and useful information on the sub-
ject.
DANGER
!
WARNINGWARNING
!
CAUTIONCAUTION
!
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Important safety instructions
10 Operating Instructions Soyer Bolzenschweißtechnik
Safety instructions
on the device
As an additional warning of danger, warning labels can be found on the devices.
Warning labels are affixed by the manufacturer and must not be removed. If a
warning label is damaged and thus illegible, a new warning label must be affixed
immediately.
Warning labels must be obtained from the manufacturer.
2.2 General safety instructions
DANGER
!
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.
• Protection devices must not be manipulated or disabled. Protection
devices include, for example, housing and housing cover, fuses or power
switches.
• If protection devices have to be removed for maintenance work, the device
may only be switched on again when all protection devices are installed
and their functionality has been checked.
• Starting the device with faulty protection devices is not permitted. Faulty
protective devices must be repaired or replaced immediately. Unintentional
operation by third parties must be prevented.

Important safety instructions
Operating Instructions Soyer Bolzenschweißtechnik 11
DANGER
!
Danger from electric current during maintenance and repair work
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 of Soyer Bolzenschweißtechnik.
• Before performing any work on the stud welding device, the mains switch
of the device must be turned off and the mains plug must be disconnected.
• Before performing any work on the stud welding gun, the supply cables to
the stud welding device must be disconnected.
• If protection devices have to be removed for maintenance work, the device
may only be switched on again when all protection devices are installed
and their functionality has been checked.
DANGER
!
Danger from magnetic fields
In the area surrounding the device, strong magnetic fields which may influ-
ence medical auxiliary devices and therefore result in danger to life occur
during the welding process.
• Persons with electric medical aids (e.g. pacemakers) must stay away from
the devices.
• The operating personnel must ensure that persons with medical aids stay
away from the devices.
DANGER
!
Danger of explosion from inappropriate operation sites in explosive
areas
The device is not designed for use in explosive areas.
• The device must not be installed and operated in explosive areas.

Important safety instructions
12 Operating Instructions Soyer Bolzenschweißtechnik
CAUTIONCAUTION
!
Danger of burns from 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.
• Before working on hot parts of the device, check if they have cooled down.
WARNINGWARNING
!
Danger of burns from hot welding spatters
During the welding process, dangerous welding spatters may occur.
• Always use personal protective equipment.
WARNINGWARNING
!
Danger of fire from hot welding spatters
Welding spatters or hot workpieces occurring during the welding process may
cause danger of fire.
• Do not store combustible or highly flammable materials in the welding
area.

Important safety instructions
Operating Instructions Soyer Bolzenschweißtechnik 13
2.3 Personal protective equipment
It is recommended to wear personal protective equipment when working with the
stud welding device.
WARNINGWARNING
!
Danger from missing or incorrect personal protective equipment
Stud welding may lead to danger of burns, especially due to hot welding spat-
ters. Danger of blinding may also arise due to the occurrence of strong arcs.
• Always wear suitable and closed protective clothing.
• Type and extent of the required protective equipment depend on the
respective occurrence of welding spatters and/or arcs. Both occurrences
vary, depending on the basic material, stud material, stud size and the
required welding performance.
• Please observe the following instructions for protective equipment.
Recommended personal protective equipment
Safety goggles
Welding spatters and a flash occur during the welding pro-
cess. In order to protect your eyes, wear appropriate safety
goggles with side protection and a filter protector, if neces-
sary.
Protective gloves
During the welding process, the workpieces and compo-
nents of the welding gun get hot and welding spatters
occur. Wear appropriate, incombustible, heat-resistant pro-
tective gloves.
Protective clothing
Welding spatters occur during the welding process. Wear
appropriate, incombustible and, if necessary, heat-resistant
protective clothing.
Safety footwear
Welding spatters occur during the welding process. Wear
appropriate, incombustible, heat-resistant safety footwear.
Hearing protection
Relatively loud welding noises may occur, depending on
the welding device and the welding application. In that
case, wear appropriate hearing protection.

Important safety instructions
14 Operating Instructions Soyer Bolzenschweißtechnik
2.4 Intended use of the stud welding device
With the SOYER® BMS-8N capacitor discharge stud welding device, pins and
threaded studs from M3 to M8 (M3 to M10 with BMS-8NV) as well as many differ-
ent weld fasteners made of steel, stainless steel, aluminium and brass can be
welded in accordance with DIN EN ISO 13918 (capacitor discharge).
Special studs or diameters upon request.
The stud welding device can only be operated with the welding guns described in
chapter “6.5 Permitted stud welding guns” on page 24.
The stud welding device must be operated within the scope of technical data.
2.4.1 Incorrect use
Any use of the device deviating from the intended use is considered as not intended.
Not intended use, unauthorised modification or manipulation of the device will
void the declaration of conformity and warranty claims against the manufacturer.
2.5 Intended use of the stud welding guns
With the SOYER® stud welding guns, pins and threaded studs from M3 to M8
(up to M10 with special gun and adapter) as well as many different weld fasteners
made of steel, stainless steel, aluminium and brass can be welded in accordance
with DIN EN ISO 13918 (capacitor discharge).
Special studs or diameters upon request.
The stud welding gun can only be operated with the stud welding devices de-
scribed in chapter “6.4 Technical data on BMS-8N(V) stud welding device” on
page 23 and chapter “9.1 Technical data for the PS-1K stud welding gun” on
page 33.
The stud welding gun can only be operated within the scope of technical data.
2.5.1 Incorrect use
Every use of the welding gun deviating from the intended use is considered as not
intended.
Not intended use, unauthorised modification or manipulation of the device will
void the declaration of conformity and warranty claims against the manufacturer.
Misusing the gun as a tool, e.g. as a striking tool for checking the welding quality,
is not permitted.

Important safety instructions
Operating Instructions Soyer Bolzenschweißtechnik 15
2.6 Operating company prerequisites
The operating company of the device must ensure that the prerequisites de-
scribed in these operating instructions for a safe operation of the device are met.
These include, for example, conditions at the installation location, regulatory re-
quirements on a safe workplace, instruction of operating personnel and qualified
personnel in using the device, if applicable, compliance with required mainte-
nance work as well as monitoring the intended use of the device.
These operating instructions must be stored in the vicinity of the device.
The operating company of the device must ensure that all protective devices are
present, active and intact before the device is used.
2.6.1 Prerequisites for personnel
Operating
personnel
Persons authorised to operate the device must be familiar with the device and
trained accordingly. They must have read and understood these operating in-
structions. When working on the device, they must also be able to avert possible
residual danger to themselves or third parties or minimise them as far as possible.
To retain this qualification, safety training must be carried out at least once a year.
If necessary, specially trained personnel or the manufacturer must be consulted
in case of failure or for maintenance work.
Operators of stud welding devices must have technical expertise for operating
and adjusting the device properly as well as for properly carrying out weldings.
If welding personnel has to be qualified for certification of welding, the standards
DIN EN ISO 14555 and DIN EN ISO 14732 are to be observed.
Trained
electrotechnical
personnel
As a general principle, works on live elements may only be performed by qualified
electricians. This work must be performed in accordance with the applicable tech-
nical rules for electrotechnical devices.
i
All devices of Soyer Bolzenschweißtechnik GmbH must only be opened
by personnel of Soyer or personnel authorised by Soyer.

Transport
16 Operating Instructions Soyer Bolzenschweißtechnik
3. Transport
When transporting the device, make sure that it cannot be damaged. Appropriate
packaging can protect the device against weathering effects, especially moisture.
4. 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.
5. Disposal
Local environmental directives must be observed when disposing of the device.
Water-endangering as well as environmentally hazardous substances are to be
disposed of in accordance with legal regulations.
If applicable, materials must be separated according to regulations.

Description of BMS-8N(V) stud welding devices
Operating Instructions Soyer Bolzenschweißtechnik 17
6. Description of BMS-8N(V) stud welding devices
The main elements of the stud welding device and its features are described in
the following.
6.1 Type differentiation
The difference between the device types BMS-8N and BMS-8NV described in this
instruction lies in the different performances of the capacitor banks and therefore
in the welding performance.
6.2 Working method
With the SOYER® BMS-8N stud welding device, pins and threaded studs from
M3 to M8 (M10 with BMS-8NV and special gun) as well as many different weld
fasteners made of steel or stainless steel can be welded in accordance with
DIN EN ISO 13918 (capacitor discharge).
Welding of weld fasteners made of aluminium and brass is also possible.
6.2.1 Product features
• Patented “charging circuit” (Pat. No. 199 15 396.5) allowing highest welding
sequences during continuous application.
• High performance with a compact design and a small weight.
• Short charging cycles to increase productivity.
• Digital display of the charging voltage or the stud diameter.
6.2.2 Capacitor discharge stud welding
The SOYER® BMS-8N(V) stud welding device operates according to the
principle of capacitor discharge with tip ignition.
This system uses the sudden discharge of a capacitor bank to generate arc
energy.
Designation
Order number Feature
BMS-8N
P01048
Capacitor bank: 66,000 µF
Maximum welding stud diameter: M8
BMS-8NV
P01056
Capacitor bank: 99,000 µF
Maximum welding stud diameter: M8 (M10 with special
welding gun)

Description of BMS-8N(V) stud welding devices
18 Operating Instructions Soyer Bolzenschweißtechnik
Functional principle
The stud tip is placed into
contact with the work-
piece.
The ignited arc creates
a melt zone on the stud
and the metal sheet.
The stud is immersed
in the weld pool. The
material solidifies and
the stud is permanently
welded.
i
For more information on this subject, please visit: www.soyer.com.

Description of BMS-8N(V) stud welding devices
Operating Instructions Soyer Bolzenschweißtechnik 19
6.3 Overview of the controls
Figure 1: Overview of the front panel
Item Designation
a Up arrow key to increase the charging voltage or the stud diameter
(depending on the display settings).
b Display for showing the charging voltage or the stud diameter.
c Up arrow key to decrease the charging voltage or the stud diameter
(depending on the display settings).
d Display of operating states, see chapter “6.3.2 Displaying the operat-
ing states” on page 22.
e Support table for the selection of the charging voltage fitting the stud.
f Carrying handle.
g Socket for the connection of the control cable (stud welding gun).
h Socket for the connection of the welding cable (stud welding gun).
i Connector for the connection of the earth cable.
ab
h
dec
fig

Description of BMS-8N(V) stud welding devices
20 Operating Instructions Soyer Bolzenschweißtechnik
Figure 2: Overview of the back panel
Item Designation
a Mains switch for turning the device on/off.
b Fuses
c Type plate
dMains plug
ab
d
c