Soyer BMS-8N User manual

Operating Instructions
Stud Welder
BMS-8N
R

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Serial number*
Stud Welder BMS-8N
* Please enter the serial number, so that this data is immediately available if you
need service support.
Heinz Soyer Bolzenschweißtechnik GmbH
Etterschlag
Inninger Straße 14
82237 Wörthsee
Phone08153 - 885 - 0
Fax 08153 - 8030
Telex 5270 295 heso d
Operating Instructions
Stud Welder
BMS-8N

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SOYERis a registered trade mark of Heinz Soyer Bolzenschweißtechnik
GmbH.
It is prohibited to transmit or reprint this document, as well as to utilize or disclose its contents, unless this has
been expressly granted.
Non-compliance with this regulation is liable to compensation. All rights reserved, particularly in the case of a
patent grant or GM registration.
We have certified that the contents of this pamphlet correspond to the hard- and software described. Deviations,
however, cannot be excluded, so that we cannot warrant for absolute compliance. The data in this documenta-
tion, however, have been verified regularly and necessary corrections will be incorporated in future impressions.
We appreciate any suggestions for improvement.
 Heinz Soyer Bolzenschweißtechnik GmbH 1995 · All rights reserved
Subject to technical alterations
Printed in the Federal Republic of Germany
Date of issue revision 1:
Aug. 1, 2000

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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-8N
BMS-8NV
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

Contents
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Contents
1 General___________________________________________________________________________ 1-1
1.1 The following should be principally observed ...____________________________________________1-1
1.2 Application _________________________________________________________________________ 1-2
1.3 Information on the product _____________________________________________________________ 1-2
1.4 Type plate ___________________________________________________________________________ 1-2
1.5 Information on the documentation_______________________________________________________ 1-3
1.5.1 Chapters of operating instructions_______________________________________________________1-3
1.5.2 Information on operating instructions ____________________________________________________1-4
1.5.3 Conduct in the case of malfunctions _____________________________________________________1-4
1.6 Contacts and service address __________________________________________________________1-4
2 Description of stud welder________________________________________________________ 2-5
2.1 Tip ignition technology ________________________________________________________________2-5
2.2 Stud welder set-up ___________________________________________________________________ 2-5
2.3 Dimensions __________________________________________________________________________2-6
2.4 Technical data _______________________________________________________________________2-7
2.5 Block diagram _______________________________________________________________________ 2-8
3 Safety instructions________________________________________________________________ 3-9
3.1 Description of reference signs in the operating instructions __________________________________3-9
3.2 Staff qualification and training__________________________________________________________3-10
3.3 Dangers in the case of non-compliance with safety instructions _____________________________3-10
3.4 Safety-conscious working_____________________________________________________________3-10
3.5 Safety instructions for the operator/user _________________________________________________3-11
3.6 The following should be observed before starting the system ... _____________________________3-11
3.7 Before starting welding ... _____________________________________________________________3-12
3.8 Safety precautions at installation site____________________________________________________3-12
3.9 Working with the stud welder __________________________________________________________3-13
3.10 Safety instructions for maintenance, inspection and assembly works_________________________3-13
3.11 Unauthorized retrofit and spare parts production _________________________________________3-13
3.12 Inadmissible operating methods _______________________________________________________3-14
3.13 Stopping the stud welder _____________________________________________________________3-14
3.14 The "S" symbol______________________________________________________________________3-14
4 Installation of stud welder________________________________________________________ 4-15
5 Initiation_________________________________________________________________________ 5-16
5.1 Total view __________________________________________________________________________5-16
5.1.1 Operating elements __________________________________________________________________5-17
5.1.2 Display elements ____________________________________________________________________5-17
5.1.3 Connecting elements_________________________________________________________________5-17
5.1.4 Symbols ___________________________________________________________________________5-18
5.1.5 Fuse elements ______________________________________________________________________5-18
5.2 Preparation for initiation_______________________________________________________________5-19
5.2.1 Earth connection ____________________________________________________________________5-19
5.2.2 Connection of stud welding pistol ______________________________________________________5-19
5.2.3 Mains supply________________________________________________________________________5-19
5.3 Operation __________________________________________________________________________5-20
5.4 Welding parameters__________________________________________________________________5-20

Contents
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6 Quality control___________________________________________________________________ 6-21
6.1 General ____________________________________________________________________________6-21
6.2 Demands on the company ____________________________________________________________6-21
6.3 Proof of qualification _________________________________________________________________6-21
6.4 Type and scope of test _______________________________________________________________6-21
6.4.1 Standard work test __________________________________________________________________6-22
6.4.2 Simplified work test __________________________________________________________________6-22
6.5 Test execution ______________________________________________________________________6-22
6.5.1 Production of samples________________________________________________________________6-22
6.5.2 Visual inspection ____________________________________________________________________6-22
6.5.3 Tensile test _________________________________________________________________________6-23
6.5.4 Bend test __________________________________________________________________________6-23
7 Maintenance_____________________________________________________________________ 7-24
7.1 Stud welder ________________________________________________________________________7-24
7.2 Replacement of components __________________________________________________________7-24
7.3 Fuses______________________________________________________________________________7-25
8 Spare parts______________________________________________________________________ 8-26
8.1 Spare parts list for stud welder BMS-8N - Overview_______________________________________8-26
8.2 Exploded view of stud welder BMS-8N - Overview ________________________________________8-27
8.3 Spare parts list for stud welder BMS-8N - View A_________________________________________8-28
8.4 Exploded view of stud welder BMS-8N - View A__________________________________________8-29
8.5 Spare parts list for stud welder BMS-8N - View B, C and D ________________________________8-30
8.6 Exploded view of stud welder BMS-8N - View B, C and D _________________________________8-31
9 Malfunctions_____________________________________________________________________ 9-32
9.1 Error codes _________________________________________________________________________9-33
9.2 Troubleshooting _____________________________________________________________________9-34
10 Transport and storage___________________________________________________________ 10-36
11 List of standards and guidelines_________________________________________________ 11-37
12 Terms of warranty_______________________________________________________________ 12-38
Appendix A/PS-1 and PS-1K - Tip ignition
1 Adjustment of stud welding pistol_________________________________________________ A-1
1.1 Adjustment of stud holder______________________________________________________________A-1
1.2 Installation of stud holder into stud welding pistols PS-1 and PS-3K __________________________A-2
1.3 Installation of stud holder into stud welding pistols PS-1K and PS-0K _________________________A-3
1.4 Adjustment of spring pressure __________________________________________________________A-4
2 Initiation__________________________________________________________________________ A-5
2.1 Total view ___________________________________________________________________________A-5
2.2 Connecting stud welding pistols to stud welder____________________________________________A-6
2.3 Operation ___________________________________________________________________________A-6
3 Spare parts_______________________________________________________________________ A-7
3.1 Spare parts list for stud welding pistol PS-1K _____________________________________________A-8
3.2 Exploded view of stud welding pistol PS-1K ______________________________________________A-9

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

General
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1.2 Application
The SOYER®stud welder BMS-8N with tip ignition allows you to weld pins and
threaded studs of M3 - M8 or Ø3 - 7.1 mm as well as numerous various
fastening elements made of steel and stainless steel (see chapter 2.4, Techni-
cal Data). It is also possible to weld fastening elements made of aluminium and
brass depending on the respective requirements.
The visible side of the workpiece is spared to a large extent from pressure
marks or deformations, so that even thin sheet metals under 1 mm sheet
thickness retain their decorative appearance.
If you need 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
Phone [phone]
Fax [phone]
Website http://www.soyer.de (national)
http://www.soyer.com (international)
Product designation Stud welder BMS-8N
Country of origin Germany
1.4 Type plate
The type plate is located on the rear side of the stud welder. It contains the
following information:
•Manufacturer's name
•Manufacturer's address
•Country of origin
•Product designation
•Method of welding
•Date of construction
•Production number
•Performance data
•Mains connection values

General
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1.5 Information on the documentation
The following operating instructions are supplied with the BMS-8N stud welder:
•Operating instructions for stud welder BMS-8N
Order no.: P00298
For repeat-orders please contact:
Heinz Soyer Bolzenschweißtechnik GmbH
Etterschlag
Inninger Straße 14
D-82237 Wörthsee
Phone [phone]
Fax [phone]
Telex 52700295 heso d
E-mail [email protected]
[email protected]
1.5.1 Chapters of the operating instructions
The operating instructions describe the initiation and operation of the stud
welding system under normal conditions and comprise the following chapters
in detail:
•Chapter 1 "General"
Information on application and product, as well as supplementary informa-
tion
•Chapter 2 “Description of stud welder"
Description of tip ignition technology and of the stud welder
•Chapter 3" Safety instructions"
All safety regulations which are relevant with regard to initiation and opera-
tion of the stud welding system
•Chapter 4 "Installation of stud welder"
•Chapter 5 "Initiation"
•Chapter 6 "Quality control"
•Chapter 7 "Maintenance"
Maintenance measures
•Chapter 8 "Spare parts"
•Chapter 9 "Troubleshooting"
Errors, possible causes and remedies
•Chapter 10 "Transport and storage"
•Chapter 11 "List of standards and guidelines"
•Chapter 12 "Terms of warranty"

General
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1.5.2 Information on operating instructions
Legal relationship We draw your attention to the fact that the contents of these operating instruc-
tions are neither part of any former or existing arrangement, pledge or legal
relationship nor are designed for modifying the latter. All obligations of Heinz
Soyer Bolzenschweißtechnik GmbH result from the respective contract of
purchase which also comprises the complete and generally valid warranties.
These contractual warranty terms are neither extended nor restricted by the
implementation of these operating instructions.
WARNING
Do not carry out any activities on the stud welding system without specifi-
cally 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.
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". In all other cases, contact our service
department.
Important information If you require our service, please make sure that you supply the following
if service is required information:
•Customer number
•Product designation
•Serial number
•Year of construction
•Options
•Material of stud and workpiece
•Stud dimensions
This information will help us both to save time and unnecessary costs, e.g.
caused by delivering the wrong spare parts.
1.6 Contacts and service address
If you have any questions regarding the operation of the stud welding system,
retrofits or if you require service, please contact your responsible service office
or the following address:
Heinz Soyer Bolzenschweißtechnik GmbH
Etterschlag
Inninger Straße 14
D-82237 Wörthsee
Phone [phone]
Fax [phone]
Telex 52700295 heso d
E-Mail export@soyer. de
verkauf@soyer. de

Description of stud welding system
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2 Description of stud welder
2.1 Tip ignition technology
The SOYER stud welding systems with tip ignition run according to the
principle of capacitor discharge as defined in DVS Leaflet 0903 (German
Welding Society).
This system uses the abrupt discharge of a capacitor battery to generate
electric arc energy.
The electric arc is initiated via the calibrated and close-fit ignition tip on the
welding studs and welding elements. The stud weld base and the opposite
surface of the workpiece are melted on. The stud is then automatically dipped
in the thin fusion zone or liquid weld pool. After the immediate solidification of
the 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 pistol to be connected to the stud welder BMS-8N is the stud
welding pistol PS-1K with control cable.
Optionally it is possible to connect the stud welding pistols PS-0K, PS-1 and
PS-3K. These operating instructions exclusively describe the stud welder BMS-
8N.
For information regarding the stud welding pistols required and their setting,
please refer to the respective operating instructions of the stud welding pistols.
Stud tip touches work-
piece. Electric arc is
initiated.
Ignited arc generates a
thin fusion zone on stud
and workpiece.
Stud immerses in welding
pool. Material solidifies
and stud is welded.
SZ.0078.E

Description of stud welding system
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2.3 Dimensions
The stud welder BMS-8N has a handy and compact design.
It has a carrying handle and can be optionally equipped with a shoulder strap.
120
300
Depth 320 mm
SZ.0124.E
Heinz Soyer Bolzenschweißtechnik GmbH ·Etterschlag ·Inninger Str. 14 ·82237 Wörthsee ·Tel.: [phone]
R
BMS-8N
000
TÜVRheinland
geprüfte
Sicherheit
S
≈70
Ø 3
≈100
Ø 4
≈115
Ø 5
≈140
Ø 6
≈175
Ø 7
≈190
Ø 8
000

Description of stud welding system
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2.4 Technical data
Description
Welding range
Material
Welding method
Standard pistol
Current source
Charging capacity
Charging voltage
Welding time
Welding sequence
Mains supply
Fuse element
Welding cable
Earth cable
Weight
Colour
Subject to technical changes
BMS-8N
M3 - M8 or Ø3 - 7.1 mm
Steel, stainless steel. Aluminium and brass conditionally,
depending on the respective requirements
Tip ignition according to DVS Leaflet 0903
Stud welding pistol PS-1K
Capacitor battery
66,000 µF
50 - 200 V infinitely variable up/down
0.001 - 0.003 sec.
up to 20 studs/min., depending on stud diameter
115/230 V AC, 50/60 Hz, 10/16 AT shock-proof socket
(automatic voltage selection 115/230 V AC)
G - fuse link 5 x 20 mm, 2 x 10 A slow, 250 V.
The fuse links are integrated in the unit mounting
plugs at the rear side of the stud welders.
3 m highly flexible
2 x 3 highly flexible
10 kg
RAL 5009 azure
SZ.0125.E

Description of stud welding system
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2.5 Block diagram of BMS-8N
KL7
KL6
KL5
KL4
KL3
KL2
KL1
KL21
KL20
KL19
KL18
KL17
KL16
KL15
KL14
KL13
KL12
KL11
KL10
KL9
KL8
15-pole socket
10AT
PE
L1 N
Mains supply 115/230VAC 50/60Hz
10AT
I/0
K275
yellow/green
Relay
SP2 5VDC brown
black
brown
green
yellow
white
red
blue
red
blue
black
blue
blue
red
red
white
red
brown
brown
green rt
100W
22R
Discharging
resistor R
Gate
Cathode
SKR 130/16
22mF
S0115 revision 2 Machine PCB
Charge F1 6.3AT
F2 1A
Control
Ventilator
F3 250mA
Ventilator 24VDC
swred
_
+
red blue
blueblue
Charging
module
blue
130°C
20V
115V 115V
190V
white yellow green
Toroidal mains transformer BV 973 701.3
Core 25 4 turns
Core 20 5 turns
M
+
22mF
+
22mF
100W
3R9
Safety resistor
Earth Earth
Pistol
S30E4A
Core 20 5 turns
Trigger Pistol
P1
SO105 revision 1 Front panel Flat cable
26-pin
+
9
+
_
2200µF
+
_
1000µF
Measuring points
5VDC 26VDC
SZ.0178.E

Safety instructions
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3 Safety instructions
These operating instructions contain basic instructions which have to be
complied with during installation and/or operation. It is therefore absolutely
necessary that these operating instructions are read by the operator and
responsible specialist staff prior to assembly and initiation. They 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, voltages, 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
Ꮨ
safety symbol in compliance with DIN 4844 - W8
In addition to these symbols, the words "DANGER TO HEALTH" or "MORTAL
DANGER" refer to the degree of a possible danger.

Safety instructions
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Safety instructions the non-observance of which may endanger the machine
and its functions are marked with the terms
"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 welding equipment user. Furthermore,
the user must ensure that the contents of the operating instructions are fully
understood by the staff.
The training and testing institute of welding in Munich (SLV: Schweißtechnische
Lehr- und Versuchsanstalt) offers the appropriate training courses for your
personnel.
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 system 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 conse-
quences:
•Failure of important system functions
•Failure of prescribed methods for maintenance
•Danger to persons through electric, mechanic, thermal and acoustic
influences
3.4 Safety-conscious working
The safety instructions listed in this manual, existing national accident preven-
tion regulations and possible international working, operating and safety
regulations of the user must be complied with.

Safety instructions
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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
You are therefore obliged to restrict the dangers to an inevitable degree and to
point these dangers out to the operator and other persons involved.
MORTALDANGER
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 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.
MORTALDANGER
When welding, do not wear clothes soiled with easily combustible
substances such as oil, grease and paraffin oil, etc.

Safety instructions
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•Wear gauntlet gloves made of leather.
•Wear neither rings, watches nor electrically conductive jewellery.
•Wear protective goggles to protect your eyes from welding spatters and
flashes of light that are generated during the process.
•Wear ear protection. Capacitor discharge generates a loud bang.
3.7 Before starting welding ...
•Check the state of all cables before starting to weld.
•Immediately replace defective cables and cable connections.
•Ensure that the air apertures of the housing are not covered. Heat accumu-
lation may damage the stud welder.
3.8 Safety precautions at installation site
•When placing the stud welder on tables or similar workshop furniture,
ensure that the stud welding system stands firmly and that the table can
bear its weight.
•Make sure mains socket and stud welder 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.
DANGERTOHEALTH
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 are applicable for narrow rooms.

Safety instructions
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3.9 Working with the stud welder
•Comply with all accident prevention regulations which apply to the operation
of your stud welder
One of the accident prevention regulations applicable for stud
☞welders is VBG15 "Welding , cutting and similar working
methods". For more information, 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.
If an accident happens,
•switch off the stud welder and disconnect it from the mains supply
•call a doctor.
3.10Safety instructions for maintenance, inspection and assembly
works
Only carry out maintenance The user must ensure that all maintenance, inspection and assembly
works when stud welder has works are only carried out by authorized and qualified technical personnel.
been switched off Generally, only work at the system when it has been switched off and after
having disconnected it from the mains supply. It is indispensable to comply
with the procedure for stopping the stud welding system described in the
operating instructions (chapter 3.13).
Immediately after having completed your work, re-install and activate all safety
and protective devices.
3.11Unauthorized 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 manufac-
turer guarantee safety. The use of other parts may result in the cancellation of
warranty for any consequences thus caused.

Safety instructions
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3.12Inadmissible operating methods
Limit values Working safety of the stud welding system supplied can only be guaranteed
when the stud welder is used in accordance with its purpose. The limit values
indicated in the chapter "Technical data" must never be exceeded.
3.13Stopping the stud welder
•Switch off the mains switch (chapter 5.1, item 9) located at the stud
welder's rear side.
•Disconnect the mains plug from the socket.
•Disconnect
- the earth cables (chapter 5.1, item 5)
- the control cable (chapter 5.1, item 7)
- the welding cable (chapter 5.1, item 6)
from the stud welder.
•Roll up the cables without buckling them.
Our tool and gear wagon GW-1 is the optimum solution for
☞installing SOYER stud welders and for properly storing welding
pistols, cables, studs, retrofit kits etc.
•Make sure stud welder cannot be used by unauthorized persons.
•Check the welding cable and connections of the stud welder for damage
such as burn-off, mechanical wear etc. and have damaged parts replaced
by SOYER customer service.
3.14The "S" symbol
ᏘMORTALDANGER
The "S" symbol is the symbol for welding current sources permitted for
operation with increased electric danger. The "S" symbol on our stud
welders refers exclusively to the welding current circuit and not to the
complete stud welder.