Soyer BMS-9 ACCU User manual

EN
Operating
Instructions
Stud welding device BMS-9 ACCU
Stud welding gun PS-9K ACCU

EN
Device numbers
We recommend to enter the device numbers in the list so that they can be ac-
cessed quickly if servicing is required.
Operating Instructions
Document no.: P00162, 04-2019, translation of the original instructions
(English: P00262)
All information in this document is the property of
Heinz Soyer Bolzenschweißtechnik GmbH.
Device Type Serial number
Stud welding device BMS-9 ACCU
Battery BMS-9 ACCU
Stud welding gun PS-9K ACCU
Revision status
Document created/amended Editor Date
Original Created DD 03/05/2019

Operating Instructions Soyer Bolzenschweißtechnik 3
CONTENTS
1. General 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
2. Important safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1. Warning signs used 8
2.2. General safety instructions 9
2.3. Personal protective 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
3. Important safety instructions for battery operation . . . . . . . . . . . . . . . . . . . . 15
4. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5. Storage, shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6. Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7. Description of the BMS-9 ACCU stud welding
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . device 19
7.1. Working method 19
7.1.1 Product features 20
7.1.2 Capacitor discharge stud welding 20
7.2. Overview of the controls 21
7.2.1 Displaying the operating states 22
7.2.2 Indication of the battery charging status on the device display 23
7.3. Charging and inserting the battery 24
7.4. Technical data of the BMS-9 ACCU stud welding device 28
7.5. Permitted stud welding guns 30

4 Operating Instructions Soyer Bolzenschweißtechnik
CONTENTS
7.6. Cleaning the stud welding device 30
8. Description of the PS-9K ACCU stud welding gun . . . . . . . . . . . . . . . . . . . . . 32
8.1. Technical data of the PS-9K ACCU stud welding gun 33
8.2. Cleaning of the stud welding gun 34
9. Description of the stud chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.1. Adjusting and inserting the adjustable stud chucks 35
10. Setup and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.1. Requirements for the installation location 39
10.2. Connection of the stud welding device and the stud welding guns 40
10.2.1 Power supply 40
10.2.2 Switching the device on and off 40
10.2.3 Connecting the earth cable 40
10.2.4 Connecting the stud welding gun 42
11. Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11.1. Adjusting the charging voltage on the stud welding device 43
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. Welding defects and their causes 48
12.4. Malfunctions with an error message 49
13. Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
14. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15. Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

General information
Operating Instructions Soyer Bolzenschweißtechnik 5
1. General information
These operating instructions include important instructions and provisions for the
operation of the devices. Please keep the operating instructions at hand near 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 device BMS-9 ACCU
Stud welding gun PS-9K ACCU
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
6 Operating Instructions Soyer Bolzenschweißtechnik
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
Stud welding device
Machine type
BMS
-9 ACCU
Machine no.
_____________________
Applicable EU guidelines
RoHS directive (2011/65/EU)
Low-voltage directive (2014/35/EU)
EMC directive (2014/30/EU)
Harmonised standards
applied, in particular
EN 60974
-1:2012
EN 60974
-10:2008
National regulations applied
DGUV direc
tive 1
Date
29 March 2019
Manufacturer
- signature
Function of the signatory
CEO

General information
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]
Mail: [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://youtu.be/QrYjCVNdRZk.
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
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Also see our video instructions at
www.youtube.com/user/SoyerGmbH.

Important safety instructions
8 Operating Instructions Soyer Bolzenschweißtechnik
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
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
!
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
10 Operating Instructions Soyer Bolzenschweißtechnik
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.
The battery of battery-operated devices must be removed.
• 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
Operating Instructions Soyer Bolzenschweißtechnik 11
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
12 Operating Instructions Soyer Bolzenschweißtechnik
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
Operating Instructions Soyer Bolzenschweißtechnik 13
2.4 Intended use of the stud welding device
With the SOYER® BMS-9 ACCU 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).
Special studs or diameters upon request.
The stud welding device can only be operated with the welding guns described in
chapter “7.5 Permitted stud welding guns” on page 30.
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 which are described in these operating
instructions, 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).
Special studs or diameters upon request.
The stud welding guns can only be operated with the stud welding devices which
are described in chapter “8.1 Technical data of the PS-9K ACCU 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
14 Operating Instructions Soyer Bolzenschweißtechnik
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
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 personnel of Soyer or personnel authorised by Soyer.

Important safety instructions for battery operation
Operating Instructions Soyer Bolzenschweißtechnik 15
3. Important safety instructions for battery operation
These operating instructions describe the operation of a stud welding device
which is operated by a lithium-based high-performance battery.
The battery consists of several connected individual cells.
Due to the very high energy density and the technical design of these batteries,
the batteries must be handled very carefully.
General safety information
• Do not disassemble, open or shred batteries.
• Store batteries out of the reach of children and unauthorised persons.
• Do not expose batteries to heat or fire. Avoid storage in direct sunlight.
• Do not short-circuit batteries.
• Do not store batteries in a hazardous manner in a box or drawer where they
can short-circuit each other or can be short-circuited by other conductive ma-
terials.
• Do not expose batteries to mechanical impact.
• Only remove the battery from its original packaging right before it is used.
• If a cell is leaking, the fluid must not come into contact with the skin or the eyes.
If contact has occurred, please rinse the affected area with plenty of water and
consult a physician.
• Only use chargers which are especially designed for this type of battery.
• Always observe the polarity labels plus (+) and minus (-) on the batteries and
devices. Proper use must be ensured.
• Do not use rechargeable batteries, cells or other batteries which are not de-
signed for the use in combination with the device.
• If the connections of batteries are soiled, clean them using a dry, clean cloth.
• Keep batteries clean and dry at all times.
• Batteries must be charged before use. Always use the proper charger and ob-
serve the manufacturer’s instructions for correct charging.
• Do not charge batteries for an extended period if they are not used.
• Do not charge batteries at temperatures below 0 °C.
• The batteries may only be used in the SOYER® devices for which they are in-
tended.
WARNINGWARNING
!
Hazards due to improper battery handling
Improper handling and use of a battery may lead to electric shocks, skin irrita-
tions, chemical burns, fire or explosion.
• For safe handling and operation, the following instructions and recommen-
dations must be strictly observed.

Important safety instructions for battery operation
16 Operating Instructions Soyer Bolzenschweißtechnik
• If possible, batteries should be removed from devices, if the devices are not in
use for several weeks.
• Never use or store batteries and devices with inserted battery in an explosive
environment or in an environment with highly flammable substances.
• Ambient temperature during operation of the device: -20 °C to +50 °C.
Maintenance
• Regularly check whether the battery is in clean and dry condition.
• Use a clean and dry cloth to remove dirt.
Safe storage
• Always store batteries in a clean and dry place. Ideally store the batteries at
room temperature as a maximum or in colder environments (e. g. fridge).
• Admissible temperature during storage: -20 °C to +60 °C (recommended: 0 °C
to +20 °C).
• Do not store batteries in discharged condition. The residual capacity should be
at least 50 - 80%.
• Check stored batteries every 2 - 3 months and charge them, if required, to
prevent deep discharge which results in the destruction of the battery.
Handling of defective batteries and disposal
• Always dispose of batteries in an environmentally compatible way in accordance
with applicable local provisions. Consult the local waste disposal company.
• Never dispose of batteries in household waste.
• Do not dispatch batteries. If a battery is defective, please contact co. Soyer.
• Do not touch any leaking fluid with bare hands. Collect the fluid and dispose
of it in the correct manner. Wear goggles and protective gloves.
Dealing with battery malfunctions
Abnormal battery performance such as incorrect charging or unusually long
charging times, noticeable sudden power loss, unusual LED messages or leaking
fluids can indicate a battery defect.
• In case of obvious or suspected battery malfunctions, please consult the
service of co. Soyer.

Important safety instructions for battery operation
Operating Instructions Soyer Bolzenschweißtechnik 17
Measures in case of battery fire
• Do not touch the burning battery, not even with protective gloves. A burning
battery is extremely hot due to plasma formation!
• In case of battery fire, remove all flammable objects around the burning battery
and call the fire brigade, if required.
• Ensure sufficient ventilation to ensure that hazardous and explosive vapours
can escape.
• In case of significant smoke development, please leave the room immediately.
• In case of respiratory tract irritation, consult a physician.
• Do not fight battery fire with water. Powder extinguishers and fire blankets only
serve to extinguish surrounding fires but are not an effective method to fight
the battery fire.

Transport
18 Operating Instructions Soyer Bolzenschweißtechnik
4. Transport
When transporting the device, make sure that it cannot be damaged. Appropriate
packaging can protect the device against weathering effects, especially moisture.
5. 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.
6. 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.
i
Do not dispatch the battery. Please observe chapter “3. Important safety
instructions for battery operation” on page 15.
i
For the storage of the battery, please observe chapter “3. Important
safety instructions for battery operation” on page 15.
i
For the disposal of the battery, please observe chapter “3. Important
safety instructions for battery operation” on page 15.

Description of the BMS-9 ACCU stud welding device
Operating Instructions Soyer Bolzenschweißtechnik 19
7. Description of the BMS-9 ACCU stud welding
device
The main elements of the stud welding device and its features are described in
the following.
Figure 1: BMS-9 ACCU stud welding device
7.1 Working method
The welding capacitors with a capacity of 200 Millifarad are charged with up to
99 V using the energy from the battery (24 V). The charging unit corresponds to
a state-of-the-art inverter power source. The welding power is output exclusively
by the welding capacitors.
With the SOYER® BMS-9 ACCU stud welding device, pins and threaded studs
from M3 to M8 as well as many different weld fasteners made of steel or stainless
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.
Item Designation
a BMS-9 ACCU stud welding device
b Battery
c Battery charger
a
c
b

Description of the BMS-9 ACCU stud welding device
20 Operating Instructions Soyer Bolzenschweißtechnik
7.1.1 Product features
• Power supply via high performance battery
• Inverter switching power supply for maximum welding power
• 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
7.1.2 Capacitor discharge stud welding
The SOYER® BMS-9 ACCU 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
The stud tip is placed
into contact with the
workpiece.
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.
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For more information on this subject, please visit: www.soyer.com.