Soyer BMS-9 ACCU User manual

EN
Operating
Instructions
Automatic system
Stud welding devices BMS-9
Automatic
BMS-9V
Automatic
Stud welding gun PS-3A
Universal feeder UVR-300

EN
Device numbers
We recommend entering the device numbers here so that they can be accessed
quickly if servicing is required.
Operating Instructions
Document no.: P00164, 05-2020, Original instructions
(English: P00264)
All information in this document is the property of
Heinz Soyer Bolzenschweißtechnik GmbH.
Device Type Serial number
Stud welding device BMS-9 Automatic
BMS-9V Automatic
Stud welding gun PS-3A
Universal feeder UVR-300
Revision status
Document created/amended Editor Date
Translation of the origi-
nal manual
Created DD 20 September 2020

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 automatic system 14
2.4.1 Incorrect use 14
2.5. Operating company prerequisites 14
2.5.1 Prerequisites for personnel 15
3. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4. Storage, shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6. Description of the automatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. Description of stud welding devices BMS-9(V) Automatic . . . . . . . . . . . . . . 18
7.1. Type differentiation 18
7.2. Working method 18
7.2.1 Product features 19
7.2.2 Capacitor discharge stud welding 19
7.3. Overview of the controls 20
7.3.1 Displaying the operating states 22
7.4. Technical data on BMS-9(V) Automatic stud welding device 23
7.5. Permitted stud welding guns 24
7.6. Cleaning the stud welding device 25
8. Description of the PS-3A stud welding gun . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1. Inserting the stud feed hose 28

4 Operating instructions Soyer Bolzenschweißtechnik
CONTENTS
8.2. Technical data for the PS-3A stud welding gun 30
8.3. Cleaning the stud welding gun 31
9. Description of the stud chuck for PS-3A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.1. Adjusting the stud chuck 33
9.2. Inserting the stud chuck and stud feed pipe 34
10. Description of the UVR-300 universal feeder . . . . . . . . . . . . . . . . . . . . . . . . 37
10.1. Safety information for UVR-300 38
10.2. Overview of UVR-300 39
10.3. LED operating displays (device front panel) 42
10.4. Function keys and special functions 43
10.4.1 Special functions (potentiometer) 44
10.5. Converting the universal feeder 45
10.5.1 Carrying out the conversion 46
10.6. Adjusting the feeder 57
10.6.1 Adjusting the blow air regulator 57
10.6.2 Adjusting the blow-off nozzles 58
10.6.3 Adjusting the transport speed in the feeder bowl 59
10.6.4 Readjusting the limit switch 60
10.7. Correcting feeder malfunctions 61
10.8. Technical data for the UVR-300 64
10.9. Cleaning the UVR-300 65
11. Setup and connection of the automatic system . . . . . . . . . . . . . . . . . . . . . . 66
11.1. Requirements for the installation location 66
11.2. Connection diagram 66
11.3. Connections on the stud welding device 68
11.4. Connections on the feeder 72
11.5. Connections on the welding gun 74
11.6. Information about connecting the earth cable 75
12. Converting/adjusting the automatic system . . . . . . . . . . . . . . . . . . . . . . . . . 77
12.1. Converting the automatic system for the stud diameter 77
12.1.1 Conversion sets 77
12.2. Adjusting the device parameters 78
12.2.1 Explanation of the parameters 78

Operating instructions Soyer Bolzenschweißtechnik 5
CONTENTS
12.2.2 Adjusting the main parameters 79
12.2.3 Adjusting the ancillary parameters 81
12.3. Adjusting the charging voltage and lift time on the stud welding device 83
12.3.1 Tables for adjusting the device 83
12.3.2 Adjusting the charging voltage 85
12.3.3 Adjusting the lift time (height of lift) in the setting mode 86
13. Welding with the automatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
13.1. Starting the automatic system and carrying out welding 89
13.1.1 Refilling the feeder during operation 91
13.2. Notes on checking the quality of the weld 92
13.2.1 Visual inspection 92
13.3. Switching off the devices 94
13.4. Welding defects and their causes 95
13.5. Malfunctions with an error message on the stud welding device 96
14. Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
15. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
16. Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
17. Replacement and conversion parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
17.1. Feeder conversion set 100
17.2. Conversion and replacement parts for the gun and stud chuck 102

GENERAL INFORMATION
6 Operating instructions Soyer Bolzenschweißtechnik
1. General information
These operating instructions contain important information and rules for the oper-
ation of the devices. Keep these operating instructions in a readily accessible lo-
cation close to the devices.
In these operating instructions, the term “devices” refers to the stud welding de-
vice, the universal feeder 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 automatic system with the following de-
vices:
1.2 Declarations of conformity
The devices are designed and constructed in accordance with the general ac-
cepted codes of practice.
Stud welding device BMS-9 Automatic
BMS-9(V) Automatic
Stud welding gun PS-3A
Universal feeder UVR-300
i
Please note that significant changes to the devices will cause the decla-
ration of conformity to become void.
Furthermore, the manufacturer's warranty may be rendered invalid.

GENERAL INFORMATION
Operating instructions Soyer Bolzenschweißtechnik 7
Conformity Declaration Automatic System Stud Welding
EC Declaration of Conformity
in accordance with the EC Machinery Directive 2006/42/EC of 17 May 2006,
Annex II A
We herewith declare that the design and construction of the machine described below as well as in the
version marketed by us meet the fundamental safety and health requirements of the EC Directive
2006/42/EC.
Any modification of this machine without our confirmation shall automatically annul this declaration.
Manufacturer:
Heinz Soyer Bolzenschweißtechnik GmbH,
Inninger Straße 14
D-82237 Wörthsee, Germany
Phone: [phone]
Description of the machine:
• Function: Stud welding system (unit consisting of feeder and stud welding device)
• Type/Model: BMS-9 Automatic / BMS-9V Automatic
• Serial number: ________________
• Year of manufacture: ________________
The product is conform with other directives/regulations applicable to the
product:
• EC Low Voltage Directive 2006/95/EC
• EMC Directive (2004/108/EC) of 15 December 2004
Harmonised standards applied, in particular:
•DIN EN 12100-2011-03 Safety of machinery - General principles for design, risk assessment
and risk reduction
•DIN EN 60204-1 Safety of machinery - Electrical equipment of machines, Part 1: General
requirements
xDIN EN 60974-1 Arc welding equipment; Part 1: Welding power sources
Other technical standards and specifications applied:
xDIN EN ISO 4414 Fluid power - General rules and safety requirements for pneumatic systems
and their components
Responsible person for the technical documentation:
Mr Klein, Soyer Company
Place/date: Wörthsee, 24 August 2018
Undersigned person:
Heinz Soyer, Managing Director
Signature:
________________

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.
Information on the scope and costs of instruction and training can be obtained
from Soyer GmbH.
1.5 Standards and directives
The following standards, among others, must be observed for carrying out stud
welding work and for the qualification of personnel:
• DIN EN ISO 14555 Welding - Arc welding of metallic materials
• DIN EN ISO 14732 Welding personnel - Qualification testing of welding oper-
ators and weld setters for mechanised and automatic welding of metallic ma-
terials
• DIN EN 60974-9 Arc welding equipment - Installation and use
• Technical Bulletin DVS 0903 Capacitor discharge stud welding (CD)
• Technical Bulletin DVS 0904 Instruction for practice - Arc 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
!
WARNING
WARNING
!
CAUTION
CAUTION
!
i

IMPORTANT SAFETY INSTRUCTIONS
10 Operating instructions Soyer Bolzenschweißtechnik
Safety informa-
tion on the de-
vices
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 cur-
rent.
• 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
protection 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 cur-
rent.
• Work on electric or electronic components may only be performed by
trained electrotechnical personnel of Soyer Bolzenschweißtechnik.
• Before performing any work on the device, the mains switch of the device
must be turned off and the mains plug must be disconnected.
• Before performing any work on the device, the supply cables to the 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 devices, strong magnetic fields occur during the
welding process, which may influence medical auxiliary devices and therefore
result in danger to life.
• 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 devices are not designed for use in explosive areas.
• The devices 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
automatic system.
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.
Filter protector recommendation: Corresponding to the
standards DIN EN 166 and DIN EN 169.
Protective gloves
During the welding process, the workpieces and compo-
nents of the welding gun get hot and welding spatters
occur. Wear appropriate, non-flammable, heat-resistant
protective gloves.
Protective clothing
Welding spatters occur during the welding process. Wear
appropriate, non-flammable and, if necessary, heat-resist-
ant protective clothing.
Safety footwear
Welding spatters occur during the welding process. Wear
appropriate, non-flammable, 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 automatic system
The automatic system for stud welding described here consists of the following
individual devices:
These operating instructions and the declaration of conformity only apply if the
named devices are used together as described in these operating instructions.
With the SOYER® BMS-9 Automatic capacitor discharge stud welding device,
pins and threaded studs from M3 to M8 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).
In connection with the PS-3A stud welding gun and the UVR-300 universal feed-
er, the studs can be fed into the gun automatically using compressed air.
Special studs or diameters upon request.
In automatic mode, the stud welding device may only be operated with the acces-
sories described in these instructions.
The devices described here can also be operated separately in other combina-
tions. If these are used outside of the automatic system, the operating instructions
for the respective device must be observed.
2.4.1 Incorrect use
Any use of the automatic system deviating from the intended use is considered
as not intended.
Not intended use, unauthorised modification, separate device operation or manip-
ulation of the devices will void the declaration of conformity and warranty claims
against the manufacturer.
2.5 Operating company prerequisites
The operating company of the automatic system must ensure that the prerequi-
sites described 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 automatic system.
Stud welding device BMS-9 Automatic
BMS-9(V) Automatic
Stud welding gun PS-3A
Universal feeder UVR-300

IMPORTANT SAFETY INSTRUCTIONS
Operating instructions Soyer Bolzenschweißtechnik 15
These operating instructions must be stored in the vicinity of the automatic sys-
tem.
The operating company of the automatic system must ensure that all protection
devices are present, active and intact before the device is used.
2.5.1 Prerequisites for personnel
Operating per-
sonnel
Persons authorised to operate the automatic system must be familiar with the au-
tomatic system and trained accordingly. They must have read and understood
these operating instructions. When working on the automatic system, they must
also be able to avert possible residual danger to themselves or third parties or
minimise them as far as possible.
To retain the 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 electro-
technical person-
nel
In general: Works on live elements may only be performed by authorised electri-
cians. This work must be performed in accordance with the applicable technical
rules for electrotechnical devices.
i
All devices of Soyer Bolzenschweißtechnik GmbH must only be opened
by Soyer personnel or personnel authorised by Soyer.

TRANSPORT
16 Operating instructions Soyer Bolzenschweißtechnik
3. Transport
When transporting the devices, ensure that they 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 devices against dirt and hu-
midity.
Protect the devices 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 THE AUTOMATIC SYSTEM
Operating instructions Soyer Bolzenschweißtechnik 17
6. Description of the automatic system
The automatic system consists of the individual devices:
With the automatic system, the welding studs are automatically fed into the weld-
ing gun.
Stud welding devices BMS-9 Auto-
matic or BMS-9(V) Automatic
(See chapter “7. Description of stud
welding devices BMS-9(V) Automatic”
on page 18)
PS-3A stud welding gun
(See chapter “8. Description of the PS-
3A stud welding gun” on page 27)
UVR-300 Universal feeder
(See chapter “10. Description of the
UVR-300 universal feeder” on
page 37)

DESCRIPTION OF STUD WELDING DEVICES BMS-9(V) AUTOMATIC
18 Operating instructions Soyer Bolzenschweißtechnik
7. Description of stud welding devices BMS-9(V)
Automatic
The main elements of the stud welding de-
vice and its features are described in the fol-
lowing.
7.1 Type differentiation
The difference between the device types BMS-9 Automatic and BMS-9V Auto-
matic described in these instructions lies in the different performances of the ca-
pacitor banks and therefore in the welding performance.
7.2 Working method
With the SOYER® BMS-9 Automatic stud welding device, pins and threaded
studs from M3 to M8 (M10 with BMS-9V Automatic and special gun, not in the au-
tomatic system!) as well as many different weld fasteners made of steel or stain-
less steel can be welded in accordance with DIN EN ISO 13 918 (capacitor
discharge).
Welding of weld fasteners made of aluminium and brass is also possible.
Automatic mode In connection with the PS-3A stud welding gun and the UVR-300 universal feed-
er, the studs can be fed into the gun automatically using compressed air.
Designation
Order number Feature
BMS-9 Automatic
P01073
Capacitor bank: 66,000 µF
Maximum welding stud diameter: M8
BMS-9V Automatic
P01074
Capacitor bank: 99,000 µF
Maximum welding stud diameter: M8
(Ø 10 mm with special gun PS-3K Stativ, no automatic
gun, therefore not in the automatic system!)

DESCRIPTION OF STUD WELDING DEVICES BMS-9(V) AUTOMATIC
Operating instructions Soyer Bolzenschweißtechnik 19
7.2.1 Product features
• Simple selection of welding parameters via function keys
• Automatic detection of the mains voltage 115/230 V~
• Inverter switching power supply for maximum welding power
• Automatic detection of the welding gun (gap/contact)
• Control of the LED illuminated ring for welding gun PS-9(K) (Not an automatic
gun, therefore not in the automatic system!)
• High performance with a compact design and a low weight
• Automatic storage of the charging voltage
• Short charging cycles to increase productivity
• Precise digital display of the charging voltage
• Monitoring of all functions via a clear function display field
7.2.2 Capacitor discharge stud welding
The SOYER® BMS-9 Automatic 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 en-
ergy.
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 STUD WELDING DEVICES BMS-9(V) AUTOMATIC
20 Operating instructions Soyer Bolzenschweißtechnik
7.3 Overview of the controls
Figure 1: Overview of the front panel of BMS-9 Automatic
Item Designation
a Mains switch for turning the device on/off
b Selection keys to quickly and directly preselect the stud diameters
and the charging voltage (see chapter “12.3.1 Tables for adjusting the
device” on page 83).
BMS-9: Ø 3 - Ø 4 - Ø 5 - Ø 6 - Ø 7.1 - Ø 8 mm
BMS-9V: Ø 3 - Ø 4 - Ø 5 - Ø 6 - Ø 8 - (Ø 10 mm with special gun, not
automatic system!)
c Function key to reduce displayed charging voltage
d Display of operating states, see chapter “7.3.1 Displaying the operat-
ing states” on page 22.
e Function key to increase displayed charging voltage
f Display
g Mains cable
h Connection of gun hose package: Plunger back
i Connection of gun hose package: Plunger forward
j Connection of the earth cable
k Connection of gun hose package: Connection socket for control cable
l Connection of gun hose package: Connection of welding cable
R
BMS-9
TÜVRheinland
geprüfte
Sicherheit
S
Heinz Soyer Bolzenschweißtechnik GmbH · Inninger Str. 14 · D-82237 Wörthsee · Germany · Tel.: [phone] · www.soyer.com
M 10A
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Ø3 Ø4 Ø5 Ø6 Ø7,1 Ø8
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