Soyer BMS-9 ACCU User manual

Operating Instructions
BMS-9
BMS-9 V
Stud Welders

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Operating Instructions
BMS-9 / BMS-9 V Stud Welders
Serial number*
BMS-9 / BMS-9 V Stud Welders
_________________________
Please enter the serial number here to have it immediately
available if you need service support.
Order No.
Code designation
Note
P01070
BMS-9
Capacitor bank 66,000 μF
PO1071
BMS-9 V
Capacitor bank 90,000 μF
Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 - 82237 Wörthsee - Germany
Tel.: [phone] –Fax: [phone] - www.soyer.de

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Thank you!
Congratulations on purchasing the BMS-9 SOYER®stud welder.
You have made an excellent choice. Your BMS-9 SOYER®stud welder was specially
developed for the high-speed fastening of SOYER®weld studs in compliance with DIN
EN ISO 13 918 (capacitor discharge) on metallic, weldable workpieces.
Our devices have been tested with regard to safety requirements and
correspond to the currently valid European and national guidelines. Proof of
conformity has been established and the manufacturer is in possession of the
corresponding documents.
FOR YOUR SAFETY
Read all of these operating instructions prior to start-up. Please
follow all safety precautions as well as all chapters of these
operating instructions before starting to weld. Non-compliance with
the safety precautions can result in serious personal injuries or
death.
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 a GM registration.
We have verified 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 illustrations contained in this instruction manual may vary in some details from
your product. This, however, has no influence on the handling of the machine.
The data in this documentation have been verified regularly and necessary corrections
will be incorporated in future impressions. Any suggestions for improvement will be
appreciated.
Date of issue: October 18, 2010
Revision1: April, 2012
© Heinz Soyer Bolzenschweißtechnik GmbH 2012 · All rights reserved
Printed in the Federal Republic of Germany

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Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
82237 Wörthsee
EC Conformity Declaration
We herewith declare that the machine described in the following and the version available on
the market correspond in its design and construction to the fundamental safety and health
requirements stipulated by EC Directive on Machinery. Any modification of this machine
without confirmation shall automatically annul this declaration.
Designation of machine : Stud welder
Machine type : BMS-9 / BMS-9 V
Machine no. : ______________________
Applicable EC directives : DIN EN 60974-10
EC Directive on Low Voltage (2006/95/EC)
EC Directive on EMC (2004/108/EC)
Applied harmonised
standards, in particular : DIN EN 60 974 - 1
Applied national standards BGV A1, BGV A2, BGV A3, VBG 5
and technical specifications,
in particular : VDE 0544
Date : September 01, 2010
Producer’s signature : ___________
Signer’s function : Managing Director

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Table of contents
1Safety precautions................................................................................................................ 8
1.1 Description of reference signs in the operating instructions ................................................ 10
1.2 Staff qualification and training.............................................................................................. 11
1.3 Dangers in the case of non-compliance with safety instructions......................................... 11
1.4 Before starting to weld... ...................................................................................................... 11
1.5 Working with the stud welding equipment............................................................................ 11
1.6 Inadmissible operating methods .......................................................................................... 11
1.7 Stopping the stud welder...................................................................................................... 11
2General................................................................................................................................. 12
2.1 The following should be principally observed... ................................................................... 12
2.2 Intended use ........................................................................................................................ 12
2.3 Marketing and service.......................................................................................................... 12
2.4Information on the documentation ....................................................................................... 12
2.5 Information on the documentation ....................................................................................... 12
2.5.1 Conduct in the case of malfunctions................................................................................ 13
3Description of stud welder................................................................................................. 14
3.1 Description ........................................................................................................................... 14
3.2 Capacitor discharge stud welding technology...................................................................... 14
3.3 Technical data...................................................................................................................... 15
4Installation of stud welder.................................................................................................. 16
5Start-up................................................................................................................................. 17
5.1 Front view............................................................................................................................. 17
5.1.1 Operating elements ......................................................................................................... 18
5.1.2 Fuse element................................................................................................................... 20
5.1.3 Connecting elements....................................................................................................... 20
5.2 Preparation for start-up........................................................................................................ 21
5.2.1 Earth connection.............................................................................................................. 21
5.2.2 Connection of stud welding gun....................................................................................... 21
5.2.3 Power supply ................................................................................................................... 21
5.3 Operation.............................................................................................................................. 22
5.4 Notes with regard to the "Lifting test" operation mode......................................................... 23
6Instructions for the adjustment of stud welding guns.................................................... 24
6.1 Start-up of PS-9 welding gun with adjustment-free stud chuck........................................... 24
6.2 Basic setting of the stud chuck with adjusting screw........................................................... 27
6.3 Start-up of PS-1K welding gun............................................................................................. 28
6.4 Start-up of PS-9 welding gun (stud chuck with adjusting screw)......................................... 30
7Quality control (stud welding) ........................................................................................... 33
7.1 General instructions ............................................................................................................. 33
8Maintenance......................................................................................................................... 34
8.1 Important instructions........................................................................................................... 34
8.2 Important instructions for all service works.......................................................................... 34

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8.3 Cleaning............................................................................................................................... 34
8.3.1 Detergents for cleaning the housing................................................................................ 34
8.4 Replacement of components ............................................................................................... 34
9Troubleshooting.................................................................................................................. 35
9.1 Malfunctions......................................................................................................................... 35
9.2 Error codes (error messages on digital 7 segment display) ................................................ 36
10 Transport and storage........................................................................................................ 37
11 Terms of warranty............................................................................................................... 37
12 List of standards and guidelines....................................................................................... 38

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1 Safety precautions
These safety precautions are for your safety.
General safety instructions
Become trained and read and follow all safety precautions listed below as well as all
chapters of this manual before starting to weld.
Non-compliance with the safety precautions can result in personal injuries or
death.
Only qualified persons are allowed to install, operate and maintain the equipment.
Keep away children and juveniles under the age of 16 years from the equipment.
WARNING
It is prohibited to open the stud welder.
The service personnel are required to meet special qualifications.
Our after-sales service has adequately trained personnel, suitable service equipment
and the means to carry out all necessary works.
Warning of electromagnetic fields
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, airbags).
Ensure that the welding equipment is not operated near electronically sensitive life-
supporting equipment, such as in intensive care units in hospitals.
Persons with pacemakers must neither operate the stud welding equipment nor stay
near it while it is running.
Electric shock can cause death
Prevent electric shock by insulating your body from work and ground. Stand on dry
insulating material and wear rubber soled shoes.
Inspect all cables including power cord for damage, wear or bare wiring. Immediately
replace damaged or worn cables.
Always ensure the correct supply voltage in accordance with the data plate. Never
connect the battery charger to a power supply network with incorrect supply voltage.
Always disconnect the battery charger from the mains supply before starting any
cleaning works. Only trained and appropriately qualified personnel are allowed to carry
out works at the electric mains supply and welding system.
Do not touch live electrical parts with bare hand. Wear dry, hole-free insulating gloves.
Do not wear rings, watches or electrically conductive jewellery.
Keep the work area, studs, stud chucks, guns, cables, power source as well as your
clothes dry.

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Fumes and gases can cause damage to your health
Fumes and suspended matters may be generated during welding. Beware of fumes
detrimental to health, particularly when using surface treated materials. Please also
observe the safety regulations applicable for your country.
Do not breathe fumes and gases. Use adequate ventilation in the work area to remove
fumes and gases.
Welding can cause fire and explosions
Welding sparks and heat from flames and arcs can cause fires. Have a portable fire
extinguisher handy for immediate use. Be sure you are trained for properly using it.
When welding, do not wear clothes soiled with easily combustible substances such as
oil, grease and paraffin oil etc.
Comply with the fire regulations and do not weld, for instance, in hazardous locations.
Pay attention to flammable objects at the welding place. All flammable materials and
liquids, such as oil, fuel, etc. must be removed prior to the start of work.
Electronic equipment (e.g. airbags) and the use of explosive substances for fuel supply
require further safety precautions when carrying out welding operations on cars.
Appropriate information can be obtained from the trade associations or the car
manufacturers.
Skin and eye protection
Arc rays and welding spatters can injure eyes and skin.
Wear safety glasses with side shields and protective goggles with correct shade of filter
to protect your eyes from welding spatters and flashes of light that are generated during
the welding process.
Wear gauntlet gloves made of leather and non-combustible closed working clothes such
as heavy long-sleeve shirts, cuffless pants and safety shoes.
Wear a leather apron to protect your clothes from welding spatters.
Keep sleeves and collars buttoned and remove open pockets from the front side of your
clothing.
We recommend using ear protection. Some welding and working processes may
generate loud noises.

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1.1 Description of reference signs in the operating instructions
The non-observance of safety instructions such as pictographs and warning words can cause damage
to persons. The safety instructions of this manual describe the following:
Safety instructions
Danger!
Warning!
Immediate hazards which could result in serious personal injuries or loss of
life.
Potential hazards which could result in serious personal injuries or loss of
life.
Caution!
Caution!
Potential hazards which could result in minor personal injuries.
Warning of damage
Note!
Important!
Potential detrimental situation which may cause damage to the product or
to an object surrounding it.
Instructions for application and other useful information facilitating the
proper use of the product.
Safety symbols
The following pictographs for warnings, bans and decrees are used in this manual:
Ban for persons with
pacemakers
Ban (only in combination
with an additional safety
symbol)
Do not touch
Housing is current-
carrying
Fire extinguisher
Warning of a danger
spot
Warning of dangerous
electric voltage
Warning of
electromagnetic field
Warning of moving
parts
General ban (only in
combination with an
additional safety
symbol)
Warning of inflammable
substances
Warning of explosive
substances
Eye protection required
Protective clothing
required
Ear protection
required
Protective gloves
required

General instructions are marked with the hand symbol.

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1.2 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 have 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 user. Furthermore, the user must ensure that the contents of the operating instructions
are fully understood by the staff.
The society of welding institutes (GSI: Gesellschaft der Schweißtechnischen Institute mbH) offers the
appropriate training courses for your personnel.
For information on branches, please refer to website http://www.dvs-ev.de.
1.3 Dangers in the case of non-compliance with safety instructions
The non-compliance with safety instructions may not only endanger persons, but also the equipment
and its environment. Any non-compliance with safety instructions may result in a complete loss of
damage claims.
Failure of important system functions
Failure of prescribed methods for maintenance
Danger of persons through electric, mechanic, thermal and acoustic influences
1.4 Before starting to weld...
Check the state of all cables and cable connections before starting to weld
Immediately replace defective cables and cable connections
1.5 Working with the stud welding equipment
Comply with all accident prevention regulations which apply to the operation of your welding device.
If an accident happens,
switch off the welding device and disconnect it from the mains supply and
call a doctor
1.6 Inadmissible operating methods
Limit values
Working safety of the stud welding equipment supplied can only be guaranteed when the system is
used in accordance with its purpose. The limit values indicated in the chapter “Technical data” must
never be exceeded.
1.7 Stopping the stud welder
Turn off the stud welder’s mains switch (chapter 5.1, item 1)
Disconnect the mains plug from the mains socket
Disconnect the earth cable, control cable and welding cable from the stud welder
Roll up the cables without buckling them
Prevent the stud welder being operated by unauthorized personnel
Check welding cable and connections of the stud welder for damage such as burn-off,
mechanical wear etc. and have damaged parts replaced by the SOYER®customer service

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2 General
2.1 The following should be principally observed...
With the BMS-9 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 installing the stud welder, please 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 start-
up. Each operator should confirm this per signature.
• Prevent the stud welder being operated by unauthorized personnel.
• Only trained personnel may operate the stud welder.
• Call a doctor in case of an accident.
2.2 Intended use
The BMS-9 SOYER®capacitor discharge stud welder allows you to weld pins and threaded studs from
M3 - M8 (M10 with BMS-9 V) or Ø 3 - 7.1 mm and many other types of weld fasteners in accordance
with DIN EN ISO 13918 (capacitor discharge) manufactured of steel, stainless steel, aluminum and
brass.
2.3 Marketing and service
If you have any questions regarding the operation of the stud welder, retrofits for special applications
or if you require service, please contact your responsible service office or the following address:
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
D-82237 Wörthsee
Telephone [phone] Telefax [phone]
www.soyer.com [e-mail]
2.4 Information on the documentation
The following operating instructions are supplied with the BMS-9 / BMS-9 V stud welders:
• Operating instructions for BMS-9 / BMS-9 V stud welders
2.5 Information on the documentation
Legal relationship
We draw your attention to the fact that the contents of these operating instructions 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.
CAUTION
Do not carry out any actions on the stud welding equipment without specifically
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.

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2.5.1 Conduct in the case of malfunctions
If malfunctions occur, first try to detect and eliminate the causes according to the "Troubleshooting" list
in chapter 9 of these operating instructions. In all other cases, please contact our service department.
If you require our service, please make sure that you supply us with the following information:
• Customer number • Product designation / options
• Serial number • Year of construction
• Stud and workpiece material • Stud dimensions
This information will help us both to save time and unnecessary costs, e.g. caused by delivering the
wrong spare parts.

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3 Description of stud welder
3.1 Description
The BMS-9 SOYER®capacitor discharge stud welder allows you to weld pins and threaded studs from
M3 - M8 (M10 with BMS-9 V) or Ø 3 –7.1 mm and many other types of weld fasteners in accordance
with DIN EN ISO 13918 (capacitor discharge) manufactured of steel, stainless steel, aluminum and
brass.
For the first time, it is possible for operators to view all important operating conditions with the
help of an LED display using the traffic light principle on the welding gun. This makes the
operator’s job far easier and also considerably contributes to increasing the quality of the weld
joints.
Product highlights
■ Simple selection of the 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 display on the PS-9 welding gun
■ High capacity with compact structure and low weight
■ Automatic storage of charging voltage
■ Short charging cycles to increase productivity
■ Precise digital displaying of the charging voltage
■ Monitoring of all functions using a clear functional display panel
3.2 Capacitor discharge stud welding technology
The BMS-9 SOYER®stud welder runs according to the principle of capacitor discharge with tip ignition
as defined in DVS Leaflet 0903 (DVS = German Welding Society).
This system uses the sudden discharge of a capacitor battery to generate arc energy.
Stud tip touches workpiece
Ignited arc generates a fusion
zone on stud and workpiece
Stud is plunged into the welding
pool. Material solidifies and stud
is welded
For further information, please refer to www.soyer.de
IMPORTANT INFORMATION
Ensure that the surface is electroconductive.
Grind coated parts

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3.3 Technical data
Description
BMS-9/BMS-9 V
Welding process
Capacitor discharge stud welding
Standard gun
PS-9
Welding range
M3 - M8 or Ø 3 - 8 mm with steel, stainless steel, aluminium and brass
(M8 or Ø 8 in aluminium and brass conditionally, depending on the
respective requirements)
Power source
Capacitor bank 66,000 μF (option: BMS-9 V 99,000 μF)
Charging voltage
50 - 200 V infinitely variable up/down
Welding sequence
Up to 20 studs/min (depending on stud diameter and type of feed)
Power supply
Automatic recognition 115/230 V, 50/60 Hz, 10 A
Fuse
M 10 A (fuse 5x20mm medium time-lag)
Type of cooling
F
System of protection
IP 21
Dimensions
295 x 170 x 295 mm (w x h x d)
Weight*
8.5 kg
Colour
RAL 5009 azure
Technical specifications are subject to change without notice
WARNING
The "S" symbol is the symbol for welding current sources permitted for operation with
increased electrical danger. The "S" symbol on our stud welders refers exclusively to
the welding current circuit and not to the complete stud welder.
* Slight deviations are possible depending on accessories.

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4 Installation of stud welder
• Only install the stud welder on an even surface. The pads located on the bottom of the
welding equipment guarantee its anti-skid position and serve as vibration dampers.
• Although the stud welder is resistant to environmental influences, it should be protected against
dampness and dust.
• Please pay particular attention to the bearing strength of the workshop furniture and ensure a safe
and stable position of the welding equipment.
• Make sure there is sufficient free space around the air apertures, otherwise the device safety
mechanism will respond and interrupt the welding process.
• Install the stud welder close to the welding location.
• Ensure sufficient ventilation of the working room when operating the welding system.
NOTE
The housing of the stud welder corresponds to safety class IP 21. Please observe that
this system of protection is not suitable for being operated or transported in the rain.
• Ensure correct connected loads for electrical connections as indicated on the type plate
and charging device.

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5 Start-up
5.1 Front view
1 Mains switch
6 Digital 7-segment display
2 Selection keys
7 Mains cable
3 Function key ↓ "Down Arrow"
8 Earth cable socket
4 LED displays
9 Control cable socket 7-pole
5 Function key ↑ "Up Arrow"
10 Welding cable socket

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5.1.1 Operating elements
Mains switch (item 1, chapter 5.1)
The mains switch is used to switch the stud welder on and off.
Selection keys (item 2, chapter 5.1)
The selection keys [ Ø3] .. [ Ø8] ( [ Ø3] .. [ Ø10] with BMS-9 V]) allow different parameters to be
quickly selected according to the desired diameter.
NOTE
The charging voltage is pre-adjusted according to the table shown below. The charging
voltage can be adjusted via the "arrow down [↓]" or "arrow up [↑]" key depending on the
respective welding task.
NOTE
The stud welder recognises the type of gun connected.
Example Table for charging voltage (V) BMS-9 with PS-9 stud welding gun
[ Ø3]
[ Ø4]
[ Ø5]
[ Ø6]
[ Ø7,1]
[ Ø8]
70 V
100 V
115 V
140 V
175 V
195 V
Example Table for charging voltage (V) BMS-9 V with PS-9 stud welding gun
[ Ø3]
[ Ø4]
[ Ø5]
[ Ø6]
[ Ø8]
[ Ø10]
65 V
80 V
95 V
120 V
180 V
195 V
The welding parameters of the BMS-9 stud welder were determined with the PS-9 and PS-1K stud welding guns.
The charging voltages shown in the table above are standard values only. They may vary from the stated setting depending on
the type of workpiece, the workpiece thickness and the surface condition of the workpiece.
Function key "arrow down" (item 3, chapter 5.1)
The function key "arrow down" enables continuous reduction of the charging voltage e.g. for smaller
stud diameters.
LED displays (item 4, chapter 5.1)
The four LED displays show the respective operating states.
Symbol
Designation
Function
LED "Ready"
LED lights up when stud welder is ready for
operation.
LED "Stud
on Workpiece"
LED lights up when earth terminal of stud welder
is connected and stud touches the workpiece.
LED "Release"
LED lights up when pressing trigger switch of
welding gun.
LED "Malfunction"
LED lights up when stud welder fails.

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Function key "arrow up" (item 5, chapter 5.1)
The function key "arrow up" enables continuous increase of the charging voltage e.g. for larger stud
diameters.
Digital 7-segment display (item 6, chapter 5.1)
The digital 7-segment display shows the set energy (charging voltage in volts)
Depending on the respective operating state, other messages may be displayed.

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5.1.2 Fuse element
The BMS-9 stud welder is protected by the following fuse:
- Power input fuse: 1 x M 10 A medium time lag (front panel item 7, chapter 5.1)
5.1.3 Connecting elements
Earth cable socket (item 8, chapter 5.1)
The earth cable socket serves to connect the ground clamps to the stud welder.
Control cable socket (item 9, chapter 5.1) and welding cable socket (item 10, chapter 5.1)
The control cable connection and the welding cable socket serve to connect the welding gun to the
stud welder.
Mains cable (item 7, chapter 5.1)
The power cable is used to connect the stud welder to the power supply.
In the electrical connection, comply with the correct connection values
according to the type plate at the stud welder.