Soyer BMS-8N User manual
EN
Operating
Instructions
Stud welding devices BMS-8N
BMS-8NV
Stud welding guns PS-1 and PS-1K
PS-3K(Stativ)
PS-0K
EN
Device numbers
We recommend to enter the device numbers in the list so that they can be
accessed quickly if servicing is required.
Operating Instructions
Document no.: P00198, 10-2018, translation of the original instructions
(English: P00298)
All information in this document is the property of
Heinz Soyer Bolzenschweißtechnik GmbH.
Device Type Serial number
Stud welding device BMS-8N
BMS-8NV
Stud welding gun PS-1
PS-1K
PS-3K
PS-3K Stativ
PS-0K
Revision status
Document created/amended Editor Date
Original Created DD 2 October 2018
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 stud welding device 14
2.4.1 Incorrect use 14
2.5. Intended use of the stud welding guns 14
2.5.1 Incorrect use 14
2.6. Operating company prerequisites 15
2.6.1 Prerequisites for personnel 15
3. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4. Storage, shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6. Description of BMS-8N(V) stud welding devices . . . . . . . . . . . . . . . . . . . . . . 17
6.1. Type differentiation 17
6.2. Working method 17
6.2.1 Product features 17
6.2.2 Capacitor discharge stud welding 17
6.3. Overview of the controls 19
6.3.1 Support table stud diameter/charging voltage 21
6.3.2 Displaying the operating states 22
6.4. Technical data on BMS-8N(V) stud welding device 23
6.5. Permitted stud welding guns 24
6.6. Cleaning the stud welding device 25
4 Operating Instructions Soyer Bolzenschweißtechnik
CONTENTS
7. Description of PS-0K stud welding gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1. Technical data for the PS-0K stud welding gun 27
7.2. Cleaning of the stud welding gun 28
8. Description of the PS-1 stud welding gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.1. Technical data for the PS-1 stud welding gun 30
8.2. Cleaning of the stud welding gun 31
9. Description of the PS-1K stud welding gun . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.1. Technical data for the PS-1K stud welding gun 33
9.2. Cleaning of the stud welding gun 34
10. Description of the PS-3K and PS-3K Stativ stud welding guns. . . . . . . . . . 35
10.1. Technical data for the PS-3K (Stativ) stud welding gun 36
10.2. Cleaning of the stud welding gun 37
11. Description of the stud chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.1. Adjusting adjustable stud chucks 38
11.2. Installing the stud chuck (gun without support) 39
11.3. Installing the stud chuck (gun with support) 41
12. Setup and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
12.1. Requirements for the installation location 43
12.2. Connection of the stud welding device and the stud welding guns 44
12.2.1 Mains connection 44
12.2.2 Connecting the earth cable 44
12.2.3 Connecting the stud welding gun 46
13. Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
13.1. Adjusting the charging voltage on the stud welding device 47
13.1.1 Switching the display 48
13.1.2 Adjusting the charging voltage 48
14. Welding operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
14.1. Carrying out welding 49
14.2. Notes on checking the quality of the weld 50
14.2.1 Visual inspection 50
Operating Instructions Soyer Bolzenschweißtechnik 5
CONTENTS
14.3. Switching off the device 52
14.4. Welding defects and their causes 53
14.5. Malfunctions with an error message 54
15. Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
16. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
17. Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
General information
6 Operating Instructions Soyer Bolzenschweißtechnik
1. General information
These operating instructions contain important information and rules for the
operation of the devices. Keep these 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:
1.2 Declarations of conformity
The devices are designed and constructed in accordance with the general
accepted codes of practice.
Stud welding devices BMS-8N
BMS-8NV
Stud welding guns PS-0K
PS-1K
PS-1
PS-3K
PS-3K Stativ
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
Operating Instructions Soyer Bolzenschweißtechnik 7
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
Machine type
Machine no.
Applicable EU guidelines
Harmonised standards
applied, in particular
National regulations applied
Date
Manufacturer - signature
Function of the signatory
Stud welding device
BMS-8N
BMS-8NV
RoHS directive (2011/65/EU) Low-
voltage directive (2014/35/EU) EMC
directive (2014/30/EU)
EN 60974-1:2012
EN 60974-10:2008
DGUV directive 1
16 July 2015
CEO
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: 0049-8153-885-0
Fax: 0049-8153-8030
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. The tutorial is available at:
https://www.youtube.com/watch?v=u4JXk8Gzsmg
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
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
!
WARNINGWARNING
!
CAUTIONCAUTION
!
i
Important safety instructions
10 Operating Instructions Soyer Bolzenschweißtechnik
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.
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