Soyer BMS-6 Operating Instructions Manual
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Soyer BMS-6 Operating Instructions Manual

Stud welder
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Operating Instructions
BMS-6 ISO
Stud Welder

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Summary of Contents for Soyer BMS-6

  • Page 1 Operating Instructions BMS-6 ISO Stud Welder...
  • Page 2 BMS-6 ISO...

  • Page 3: Operating Instructions

    BMS-6 ISO Operating Instructions BMS-6 ISO Stud Welder Serial number* BMS-6 ISO stud welder _________________________ Please enter the serial number here, so that the data is immediately available if you need service support. Heinz Soyer Bolzenschweißtechnik GmbH Etterschlag Inninger Straße 14 82237 Wörthsee...
  • Page 4 You have made an excellent choice. Your BMS-6 ISO SOYER stud welder was especially developed for high-speed fastening of insulating nails, cupped head pins and SOYER welding studs in compliance with DIN EN ISO 13 918 on metallic workpieces . is a registered trade mark of Heinz Soyer Bolzenschweißtechnik GmbH.
  • Page 5 BMS-6 ISO Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 82237 Wörthsee CE Declaration of Conformity We herewith declare that the machine described in the following and the version available on the market correspond in design and construction to the safety and health requirements of the listed guidelines and standards.

  • Page 6: Table Of Contents

    Stud welder set-up ....................... 13 View ............................14 Technical data ........................15 Circuit diagram of BMS-6 ISO ....................16 Alteration of mains voltage to 115 / 230 volt ................ 16 Safety instructions........................17 Description of reference signs in the operating instructions ..........17 Staff qualification and training ....................
  • Page 7 Cleaning ..........................30 7.2.1 Detergents ........................30 Replacement of components ....................30 Fuses ............................ 30 Spare parts for BMS-6 ISO ......................32 Spare parts for BMS-6 ISO ....................32 Troubleshooting .......................... 33 Error code overview ......................34 Troubleshooting ........................35 Transport and storage ........................
  • Page 8 BMS-6 ISO Appendix A / PS-1 and PS-1K – Capacitor discharge Adjustment of PS-1 and PS-1K stud welding guns Appendix A Appendix B / PS-1KI – Capacitor discharge Adjustment of PS-1KI stud welding gun Appendix B...

  • Page 9: General

    BMS-6 ISO 1 General The following should be principally observed... With this 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: •...

  • Page 10: Application

    • Performance data • Mains connection values Information on the documentation The following operating instructions are supplied with the BMS-6 ISO stud welder: • Operating instructions for BMS-6 ISO Order no.: P00252 For repeat-orders please contact your responsible service office or our parent...

  • Page 11: Chapters Of Operating Instructions

    BMS-6 ISO 1.5.1 Chapters of operating instructions The operating instructions describe the start-up and operation of the BMS-6 ISO stud welder under normal conditions. The present operating instructions of the BMS-6 ISO stud welder comprise the following chapters in detail: •...

  • Page 12: Conduct In The Case Of Malfunctions

    Contacts and service address If you have any questions regarding the operation of the stud welding system, retrofits or if you require service, please contact your responsible service office or the following address: Heinz Soyer Bolzenschweißtechnik GmbH Etterschlag Inninger Straße 14 D-82237 Wörthsee...

  • Page 13: Description Of Stud Welder

    1 – 3 milliseconds (0.001 – 0.003 sec.). Stud welder set-up The standard gun to be connected to the BMS-6 ISO stud welder is the PS-1 stud welding gun with control cable and support tube. Optionally it is possible to connect the PS-1KI stud welding gun for cupped head pins or the PS-3K, PS-0K, PS-1K contact guns for studs and insulating nails with ignition tip to the stud welder.

  • Page 14: View

    BMS-6 ISO View The BMS-6 ISO stud welder has a handy, compact and robust design. It has a carrying handle and can be optionally equipped with a shoulder strap. Illustration: Front view of BMS-6ISO Dimensions 300 x 120 x 320 mm (w x h x d)

  • Page 15: Technical Data

    Technical data Designation BMS-6 ISO SOYER threaded flanged studs, nails and pins as per DIN EN ISO 13918 from M3 – M6 or 2 – 5.5 mm dia, as well as Welding range cupped head pins from 2 –2.7 mm dia and 10 – 55 mm in...

  • Page 16: Circuit Diagram Of Bms-6 Iso

    BMS-6 ISO Circuit diagram of BMS-6 ISO SO105 ISO SO115Rev.3 Measuring points Front panel PC Board Machine PC Board F4 115V 5Vdc 26Vdc Flat cable F5 230V 26-pole F6 230V Trigger F7 115V Pistol charging circuit F1 6.3AT Core 20...

  • Page 17: Safety Instructions

    BMS-6 ISO 3 Safety instructions These operating instructions contain basic instructions which have to be complied with during installation or operation. It is therefore absolutely necessary that these operating instructions are read by the operator and responsible specialist staff prior to assembly and start-up.

  • Page 18: Dangers In The Case Of Non-Compliance With Safety Instructions

    BMS-6 ISO Dangers in the case of non-compliance with safety instructions The non-compliance with safety instructions may not only endanger persons, but also the welding equipment and its environment. Any non-compliance with safety instructions may result in a complete loss of damage claims.

  • Page 19: Before Starting To Weld

    BMS-6 ISO • Wear protective goggles with eye-protecting lens number 2 (DIN 58211, part 6) to protect your eyes from welding spatters and flashes of light that are generated during the welding process. • Wear side-shielded glasses. • Wear ear protection. Capacitor discharge generates a loud bang.

  • Page 20: Safety Instructions For Maintenance, Inspection And Assembly Works

    BMS-6 ISO MORTAL DANGER Persons with pacemakers must neither operate the stud welder nor stay near it. If an accident happens, • switch off the welding device and disconnect it from the mains supply • call a doctor. 3.10 Safety instructions for maintenance, inspection and assembly works...

  • Page 21: The "S" Symbol

     Our GK-2 SOYER suitcase (optional equipment) is the optimum solution for properly storing SOYER stud welders as well as welding guns, cables, studs, retrofit kits etc. • Make sure stud welder can not be used by unauthorized persons. • Check welding cable and connections of the stud welder for damage such as burn- off, mechanical wear etc.

  • Page 22: Installation Of Stud Welder

     The housing of the BMS-6 ISO 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.

  • Page 23: Start-Up

    BMS-6 ISO 5 Start-up Total view 1 Potentiometer for charging voltage 6 Earth cable connector 2 Light-emitting diodes for function control 7 Mains switch 3 Table indicating welding parameters 8 Fuses 4 Control cable connection 9 Mains connection 5 Welding cable socket 10 Type plate 5.1.1...

  • Page 24: Display Elements

    5.1.5 Fuse elements The BMS-6 ISO stud welder is protected by the following fuses: - Mains supply fuses: 2 x 10 A slow, plug-in unit (item 8, chapter 5.1) - Charging fuse F1: 6.3 A slow, control board S0-115...

  • Page 25: Preparation For Start-Up

    BMS-6 ISO - Fuse for the ventilator (optional) F3: 250 mA slow, S0-115 control board (ventilator is optionally available) WARNING Should it become necessary to replace fuses, only use fuses with the prescribed electrical values. Oversized fuses could either cause defects on the electrical system or a fire.

  • Page 26: Operation

    BMS-6 ISO MORTAL DANGER Only connect stud welder to authorized shockproof sockets. If need be, have an electrician check whether the socket is earthed. Operation • Switch on mains switch (item 7, chapter 5.1). The four LED displays (item 2, chapter 5.1) on the front panel of the stud welder shortly light up after switching the stud welder on.

  • Page 27: Welding Parameters

    BMS-6 ISO Welding parameters The welding parameters of BMS-8N stud welder were determined by means of the PS-1, PS-1K and PS-1KI stud welding guns. PS-1KI PS-1 / PS-1K Ø 2 Ø 2.6 Ø 2 Ø 3 Ø 3 Ø 4 Ø...

  • Page 28: Quality Control

    4001, section 2.1, certificate of approval for stainless steel ifBT, DIN 4113, part 2). Type and scope of test Provided that the SOYER stud welding equipment is properly used and the materials are appropriately selected, the strength of the welding joint (welding zone) will always be stronger than that of the stud or base material.

  • Page 29: Simplified Work Test

    BMS-6 ISO When in doubt, the test scope should be extended in compliance with DVS Guideline 0905, part 2, section 5.1.1. 6.4.2 Simplified work test Simplified work tests serve to check the correct setting and function of the equipment. They are carried out at the beginning of every working shift and after several hours of interruption.

  • Page 30: Maintenance

    Replacement of components Defective components may only be replaced by trained SOYER servicemen. Perfect function of your stud welder can only be guaranteed when original SOYER spare parts are used. Fuses The BMS-6 ISO stud welder is protected by the following fuses: - Mains supply fuses: 2 x 10 A slow, plug-in unit (item 8, chapter 5.1)
  • Page 31 BMS-6 ISO DANGER TO HEALTH Should it become necessary to replace fuses, only use fuses with the prescribed electrical values. Oversized fuses could either cause defects on the electrical system or a fire. MORTAL DANGER Disconnect the mains plug from the mains supply when replacing fuses.

  • Page 32: Spare Parts For Bms-6 Iso

    BMS-6 ISO 8 Spare parts for BMS-6 ISO Spare parts for BMS-6 ISO Item Qty. Designation Order No. BMS-4 ISO complete P01054 Front PC Board SO-105 ISO F04674/FA Control board SO-115 SMD F04538/FA Capacitor 22000 μF / 200 volt E01199...

  • Page 33: Troubleshooting

    The following list of errors, their causes and remedies is designed to help you eliminate any trouble immediately on the spot. If it is difficult or impossible to eliminate the trouble, please contact the SOYER customer service responsible for your area or Heinz Soyer Bolzenschweißtechnik GmbH.

  • Page 34: Error Code Overview

    BMS-6 ISO Error code overview The stud welder switches off when malfunctions occur. The charging voltage of the capacitors is internally discharged. An error message appears as code on the charging voltage display (item 2, chapter 5.1): Code Description Possible cause Safety circuit activated.

  • Page 35: Troubleshooting

     Use stud with ignition tip or reduce centre mark though system is ready for operation Control of stud welder or welding gun is defective  Inform SOYER customer service Stud is too loose in stud holder  Press stud holder together or tighten it Stud thread scorched Stud holder worn ...
  • Page 36 BMS-6 ISO Error Cause  Elimination Stud not welded with total Welding energy is set too low  Reset welding energy flange surface, deficient weld joint strength Poor earth connection  Check earth cables and earth clamps for tight fit, tighten if necessary Workpiece surface too soiled ...

  • Page 37: Transport And Storage

    SOYER customer servicemen prior to start-up  The housing of the BMS-6 ISO 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.

  • Page 38: Standards And Guidelines

    BMS-6 ISO 12 Standards and guidelines • 2014/35/EU Directive on Low Voltage • 2014/30/EU Directive on Electromagnetic Compatibility • EN 60974–1 Arc welding equipment - welding current sources • EN 60974–10 Arc welding equipment - EMC requirements • DVS Information Sheet 0901 Arc stud welding of metallic materials •...
  • Page 39 Appendix A / PS-1 and PS-1K Adjustment of PS-1 / PS-1K stud welding guns Adjustment of stud holder The stud holders of PS-1, PS-3K, PS-0K and PS-1K stud welding guns are all of the same style. When using long welding studs with the short type PS-0K and PS-1K welding guns, however, it is necessary to shorten the stud holders' stop screw (4) correspondingly.
  • Page 40 Appendix A / PS-1 and PS-1K Installation of stud holder into PS-1 and PS-3K stud welding guns The illustration below shows how to install the stud holder into the PS-1 and PS-3K stud welding guns. 1 Gun leg 4 Bellows 2 Stud holder 5 Spring piston 3 Sleeve nut...
  • Page 41 Appendix A / PS-1 and PS-1K Installation of stud holder into PS-1K and PS-0K stud welding guns The illustration below shows how to install the stud holder into the PS-1K stud welding gun. These instructions also apply to PS-0K stud welding gun. 1 Stud holder 2 Support tube •...
  • Page 42 Appendix A / PS-1 and PS-1K Adjustment of spring pressure The pressure with which the stud is pressed against the workpiece during the welding process is called spring pressure. The illustration below shows how to adjust the spring pressure of PS-1 stud welding gun which is equipped with a spring pressure indicator.
  • Page 43 Appendix A / PS-1 and PS-1K Start-up Total view The illustration below shows PS-3K stud welding gun. The indicated components are only slightly different from those of PS-1, PS-3, PS-0K and PS-1K stud welding guns. • The PS-0K and PS-1K stud welding guns are equipped with support tubes instead of gun legs (2).
  • Page 44 Appendix A / PS-1 and PS-1K Connecting stud welding guns to stud welder The stud welding guns are connected to the stud welder by means of the gun and control cables. Operation • Connect stud welder to earth • Connect stud welding gun as described in chapter 5 •...
  • Page 45 Appendix A / PS-1 and PS-1K Spare parts Spare parts list for PS-1K stud welding gun (new model) Item Qty. Description Order No. Complete PS-1K stud welding gun (new model) P02117 Support tube Ø 30 mm F03813 3 gun legs (option) F03890 3 grub screws (option) M01338...
  • Page 46 Appendix A / PS-1 and PS-1K Exploded view of PS-1K stud welding gun Appendix A /9...
  • Page 47 Appendix A / PS-1 and PS-1K Appendix A /10...
  • Page 48 Appendix B / PS-1KI Appendix B / PS-1KI / Capacitor Discharge Adjustment of PS-1KI stud welding gun................. 2 Adjustment of cupped head pin retainer ................2 Installation of cupped head pin retainer into stud welding gun ..........3 Adjustment of spring pressure ................... 4 Start-up.............................

  • Page 49: Adjustment Of Ps-1Ki Stud Welding Gun

    Appendix B / PS-1KI Adjustment of PS-1KI stud welding gun Adjustment of cupped head pin retainer Instead of a stud holder the PS-1KI stud welding gun has a cupped head pin retainer (1). The adjustment of the stud welding gun is confined to the adjustment of the spring pressure which holds cupped head pins (4) in the cupped head pin retainer.

  • Page 50: Installation Of Cupped Head Pin Retainer Into Stud Welding Gun

    Appendix B / PS-1KI Installation of cupped head pin retainer into stud welding gun The cupped head pin retainer has to be installed into the stud welding gun as follows: • Turn sleeve nut (6) anticlockwise by means of socket wrench SW17. •...

  • Page 51: Adjustment Of Spring Pressure

    Appendix B / PS-1KI Adjustment of spring pressure The pressure with which the stud is pressed against the workpiece during the welding process is called spring pressure. The following illustration shows how to adjust the spring pressure. 1 Adjusting screw 2 Grub screw Adjust spring pressure by means of adjusting screw (1) as follows: •...

  • Page 52: Start-Up

    Appendix B / PS-1KI Start-up Total view The illustration below shows PS-1KI stud welding gun Appendix B /5...

  • Page 53: Connecting Stud Welding Guns To Stud Welder

    Appendix B / PS-1KI Connecting stud welding guns to stud welder The stud welding gun is connected to the stud welder by means of gun cable and control cable. Operation • Connect stud welder to earth. • Connect stud welding gun as described in chapter 5. •...

  • Page 54: Spare Parts

    Appendix B / PS-1KI Spare parts Spare parts list for PS-1KI stud welding gun (new model) Item Qty. Description Order No. PS-1KI stud welding gun, complete (new model) P02118 Cheese-head screw M3 x 12 F03930 Contact disk M01980 Cupped head pin retainer F03928 Grub screw with spring M4 x 10 M03542...

  • Page 55: Exploded View Of Ps-1Ki Stud Welding Gun

    Appendix B / PS-1KI Exploded view of PS-1KI stud welding gun Appendix B /8...
  • Page 56 Heinz Soyer Bolzenschweißtechnik GmbH Etterschlag Inninger Straße 14 D-82237 Wörthsee Tel.: ++49-(0) 81 53 / 8 85-0 Fax: ++49-(0) 81 53 / 80 30 Internet: www.soyer.de E-Mail: info@soyer.de...

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