Soyer BMS-9 ACCU User manual

1 Operating instructions Soyer Bolzenschweißtechnik
GB
Operating
Instructions
Stud welding devices BMS-9
BMS-9V
Stud welding guns PS-9
PS-9K
PS-1K

2 Operating instructions Soyer Bolzenschweißtechnik
Device numbers
We recommend to enter the device numbers in the list so that they can be accessed
quickly if servicing is required.
Device
Type
Serial number
Stud welding device
BMS-9
BMS-9V
Stud welding gun
PS-9
Stud welding gun
PS-9K
Stud welding gun
PS-1K
Operating Instructions
Document no.: P00161, 02-2017, translation of the original instructions
(English: P00261)
All information in this document is the property of Heinz Soyer
Bolzenschweißtechnik GmbH.
Revision status
Document
created / amended
Editor
Date
Original
created
MS/IS
25.04.2019

Operating instructions Soyer Bolzenschweißtechnik 3
Contents
1General information.............................................................................................................. 5
1.1 Validity of the operating instructions ...................................................................................... 5
1.2 Declarations of conformity...................................................................................................... 5
1.3 Manufacturer.......................................................................................................................... 7
1.4 Instruction, training................................................................................................................. 7
1.5 Standards and directives........................................................................................................ 7
2Important safety instructions............................................................................................... 8
2.1 Warning signs used................................................................................................................ 8
2.2 General safety instructions..................................................................................................... 9
2.3 Personal protection equipment ............................................................................................ 12
2.4 Intended use of the stud welding device.............................................................................. 13
2.4.1 Incorrect use.................................................................................................................... 13
2.5 Intended use of the stud welding guns ................................................................................ 13
2.5.1 Incorrect use.................................................................................................................... 13
2.6 Operating company prerequisites........................................................................................ 14
2.6.1 Prerequisites for personnel.............................................................................................. 14
3Transport.............................................................................................................................. 15
4Storage, shutdown.............................................................................................................. 15
5Disposal ............................................................................................................................... 15
6Description of BMS-9(V) stud welding devices................................................................ 16
6.1 Type differentiation............................................................................................................... 16
6.2 Working method................................................................................................................... 16
6.2.1 Product features............................................................................................................... 16
6.2.2 Capacitor discharge stud welding.................................................................................... 17
6.3 Overview of the controls....................................................................................................... 18
6.3.1 Displaying the operating states........................................................................................ 19
6.4 Technical data for BMS-9(V) stud welding device............................................................... 20
6.5 Permitted stud welding guns................................................................................................ 21
6.6 Cleaning of the stud welding device .................................................................................... 22
7Description of the PS-9 and PS-9K stud welding guns................................................... 23
7.1 Type differentiation............................................................................................................... 24
7.2 Meaning of the LED ring displays ........................................................................................ 24
7.3 Technical data for PS-9(K) stud welding guns..................................................................... 25
7.4 Cleaning of the stud welding gun......................................................................................... 26
8Description of the PS-1K stud welding gun..................................................................... 27
8.1 Technical data for PS-1K stud welding gun......................................................................... 28
8.2 Cleaning of the stud welding gun......................................................................................... 29
9Description of the stud chuck............................................................................................ 30
9.1 Non-adjustable stud chucks................................................................................................. 30
9.2 Adjusting and installing adjustable stud chucks................................................................... 32
10 Setup and connection......................................................................................................... 35
10.1 Requirements for the installation location............................................................................ 35

4 Operating instructions Soyer Bolzenschweißtechnik
10.2 Connection of the stud welding device and the stud welding guns ..................................... 36
10.2.1 Mains connection......................................................................................................... 36
10.2.2 Connecting the earth cable ......................................................................................... 36
10.2.3 Connecting the stud welding gun ................................................................................ 38
11 Settings ................................................................................................................................ 39
11.1 Adjusting the charging voltage and lift time on the stud welding device.............................. 39
11.1.1 Device adjustment tables ............................................................................................ 39
11.1.2 Adjusting the charging voltage.................................................................................... 41
11.1.3 Adjusting the lift time (height of lift) in the "Setup" mode ............................................ 42
12 Welding operation............................................................................................................... 45
12.1 Carrying out welding ............................................................................................................ 45
12.2 Notes on checking the quality of the weld............................................................................ 46
12.2.1 Visual inspection.......................................................................................................... 46
12.3 Switching off the device ....................................................................................................... 48
12.4 Welding defects and their causes........................................................................................ 49
12.5 Malfunctions with an error message .................................................................................... 50
13 Maintenance and repair...................................................................................................... 52
14 Service.................................................................................................................................. 52
15 Warranty conditions ........................................................................................................... 52

5 Operating instructions Soyer Bolzenschweißtechnik
1 General information
These operating instructions contain important information and requirements for the
operation of the devices. Keep the 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:
Stud welding devices BMS-9
BMS-9V
Stud welding guns PS-9
PS-9K
PS-1K
1.2 Declarations of conformity
The devices are designed and constructed in accordance with the general accepted
codes of practice.
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.

6 Operating instructions Soyer Bolzenschweißtechnik
Stud welding device

Operating instructions Soyer Bolzenschweißtechnik 7
1.3 Manufacturer
The manufacturer of the devices is:
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
82237 Wörthsee
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.soyer.de, www.soyer.com
1.4 Instruction, training
Soyer offers optional and individual instruction in the operation of the devices.
Soyer also offers training for customer-specific use of the devices.
The tutorial is available at
https://youtu.be/QrYjCVNdRZk.
Information on the scope and costs of instruction and training can be obtained from
Soyer GmbH.
Also see our video instructions at
www.youtube.com/user/SoyerGmbH.
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 mechanized and automatic welding of metallic materials
•DIN EN 60974-9 Arc welding equipment - Installation and use
•DVS Bulletin 0903 Capacitor discharge stud welding with tip ignition(CD)
•DVS Bulletin 0904 Instruction for practice - Arc stud welding

8 Operating instructions Soyer Bolzenschweißtechnik
2 Important safety instructions
Read the following chapter 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 leading 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 damage.
Additional sign indicating danger from electric current.
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 warning.
Do not touch the surface or the housing: Shock
hazard.
Do not touch or open, danger to unauthorised persons.
Danger to persons with medical implants such as
pacemakers.
The information sign is not a warning sign. It indicates
important and useful information on the subject.

Operating instructions Soyer Bolzenschweißtechnik 9
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 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.

10 Operating instructions Soyer Bolzenschweißtechnik
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 from magnetic fields
In the area surrounding the device, strong magnetic fields which may influence
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 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.

Operating instructions Soyer Bolzenschweißtechnik 11
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.
Danger of burns from hot welding spatters
During the welding process, dangerous welding spatters may occur.
Always use personal protective equipment.
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.

12 Operating instructions Soyer Bolzenschweißtechnik
2.3 Personal protection equipment
It is recommended to wear personal protective equipment when working with the stud
welding device.
Danger from missing or incorrect personal protective equipment
Stud welding may lead to danger of burns, especially due to hot welding spatters.
Danger of blinding may also arise due to the occurrence of strong arcs.
Always wear suitable, 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
process. In order to protect your eyes, wear appropriate
safety goggles with side protection and a filter protector,
if necessary.
Protective gloves
During the welding process, the workpieces and
components of the welding gun get hot and welding
spatters occur. Wear appropriate, incombustible, heat-
resistant protective 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.

Operating instructions Soyer Bolzenschweißtechnik 13
2.4 Intended use of the stud welding device
With the SOYER® BMS-9 capacitor discharge stud welding device, pins and threaded
studs from M3 to M8 (M3 to M10 with BMS-9V) 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 device can only be operated with the welding guns described in
chapter "6.5 Permitted stud welding guns" on page 21.
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 guns can only be operated with the stud welding devices described
in chapter "7.3 Technical data for PS-9(K) stud welding guns" on page 25 and chapter
"8.1 Technical data for PS-1K stud welding gun" on page 28.
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.

14 Operating instructions Soyer Bolzenschweißtechnik
2.6 Operating company prerequisites
The operating company of the device must ensure that the prerequisites described in
these operating instructions for a safe operation of the device are met.
These include, for example, conditions at the installation location, regulatory
requirements on a safe workplace, instruction of operating personnel and qualified
personnel in using the device, if applicable, compliance with required maintenance work
as well as monitoring the intended use of the device.
These operating instructions must be stored in the vicinity of the 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 instructions. 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 technical
rules for electrotechnical devices.
All devices of Soyer Bolzenschweißtechnik GmbH must only be opened by
personnel of Soyer or by personnel authorised by Soyer.

Operating instructions Soyer Bolzenschweißtechnik 15
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.

16 Operating instructions Soyer Bolzenschweißtechnik
6 Description of BMS-9(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-9 and BMS-9V described in this
instruction lies in the different performances of the capacitor banks and therefore in
the welding performance.
Designation
Order number
Feature
BMS-9
P01070
Capacitor bank: 66,000 μF
Maximum welding stud diameter: M8
BMS-9V
P01071
Capacitor bank: 99,000 μF
Maximum welding stud diameter:
M8 (M10 with special welding gun)
6.2 Working method
With the SOYER® BMS-9 stud welding device, pins and threaded studs from M3 to M8
(M10 with BMS-9V 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.
The LED display makes the operator's job easier and also considerably contributes to
increasing the quality of the welded joints.
6.2.1 Product features
•Simple selection of welding parameters using control keys
•Automatic recognition of the mains voltage 115/230V~
•Inverter switch-mode power supply for maximum welding capacity
•Automatic recognition of the welding gun (gap/contact)
•Control of the optical LED illuminated ring on the PS-9(K) welding gun
•High capacity with compact structure and low weight
•Automatic storage of charging voltage
•Short charging cycles to increase productivity
•Precise digital display of the charging voltage
•Monitoring of all functions using a clear functional display panel

Operating instructions Soyer Bolzenschweißtechnik 17
6.2.2 Capacitor discharge stud welding
The SOYER® BMS-9 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.
Functional principle
Stud tip is placed into
contact with the workpiece
Ignited arc creates a melt
zone on the stud and the
metal sheet
Stud is immersed in the
weld pool. The material
solidifies and stud is
permanently welded
For more information on this subject, please visit: www.soyer.com.

18 Operating instructions Soyer Bolzenschweißtechnik
6.3 Overview of the controls
Figure 1: Overview of the front panel
Item
Designation
a
Mains switch for switching the device ON/OFF
b
Selection keys for quick, direct preselection of the stud diameter and
charging voltage (see chapter "11.1.1 Device adjustment tables" on page
39).
c
Function key to decrease the displayed charging voltage
d
Display of operating states, for explanation see chapter "6.3.1 Displaying
the operating states" on page 19.
e
Function key to increase the displayed charging voltage
f
Display
g
Mains cable
h
Socket for the connection of the earth cable
j
7-pin connection socket for the control cable
k
Socket for the connection of the welding cable

Operating instructions Soyer Bolzenschweißtechnik 19
6.3.1 Displaying the operating states
Figure 2: Operating states
Item
Designation
a
Ready
In normal operation, the LED lights up when the stud welding device is ready
for operation in normal mode.
b
Stud on workpiece
LED lights up when the earth terminal is connected and the stud touches
the workpiece.
c
Release
LED lights up when the release button on the welding gun is pressed.
d
Malfunction
The LED lights up when a malfunction of the stud welding device occurs.
See chapter "12.5 Malfunctions with an error message" on page 50.

20 Operating instructions Soyer Bolzenschweißtechnik
6.4 Technical data for BMS-9(V) stud welding device
Designation
BMS-9 / BMS-9 V stud welding device
Welding process
Capacitor discharge stud welding
Standard gun
PS-9
Welding area
M3 - M8 or Ø 3 - 8 mm for steel, stainless steel,
aluminium and brass (M8 or Ø 8 in aluminium and
brass conditionally, depending on the respective
requirements)
Current source
Capacitor bank 66,000 μF
(Option for BMS-9V 99,000 μF)
Charging voltage
50 - 200 V infinitely variable up/down
Welding sequence
Up to 20 stud/min (depending on stud diameter and
type of feed)
Mains connection
Automatic recognition 115/230 V, 50/60 Hz, 10 A
Fuse
M 10 A (fuse 5x20mm semi time-lag)
Type of cooling
F
Protection class
IP 21
Dimensions
295 x 170 x 295 mm (w x h x d)
Weight
BMS-9 (7.9 kg) / BMS-9V (9.1 kg)
Colour
RAL 5009 azure blue
Subject to technical changes