Soyer BMS-9 Operating Instructions Manual
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Soyer BMS-9 Operating Instructions Manual

Stud welding device, guns
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Operating
Instructions
Stud welding devices
Stud welding guns
1
Operating instructions Soyer Bolzenschweißtechnik
BMS-9
BMS-9V
PS-9
PS-9K
PS-1K

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Summary of Contents for Soyer BMS-9

  • Page 1 Operating Instructions Stud welding devices BMS-9 BMS-9V Stud welding guns PS-9 PS-9K PS-1K Operating instructions Soyer Bolzenschweißtechnik...
  • Page 2 Stud welding gun PS-9K Stud welding gun PS-1K Operating Instructions Document no.: P00161, 02-2017, translation of the original instructions (English: P00261) All information in this document is the property of Heinz Soyer Bolzenschweißtechnik GmbH. Revision status Document created / amended Editor Date...

  • Page 3: Table Of Contents

    Overview of the controls ....................... 18 6.3.1 Displaying the operating states..................19 Technical data for BMS-9(V) stud welding device ............... 20 Permitted stud welding guns ....................21 Cleaning of the stud welding device ..................22 Description of the PS-9 and PS-9K stud welding guns ........... 23 Type differentiation .......................
  • Page 4 Visual inspection ......................46 12.3 Switching off the device ....................... 48 12.4 Welding defects and their causes ..................49 12.5 Malfunctions with an error message ..................50 Maintenance and repair ...................... 52 Service ..........................52 Warranty conditions ......................52 Operating instructions Soyer Bolzenschweißtechnik...

  • Page 5: General Information

    The devices are designed and constructed in accordance with the general accepted codes of practice. 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. Operating instructions Soyer Bolzenschweißtechnik...
  • Page 6 Stud welding device Operating instructions Soyer Bolzenschweißtechnik...

  • Page 7: Manufacturer

    Fax: 0049-8153-8030 Email: info@soyer.de Web: www.soyer.de, www.soyer.com Instruction, training Soyer offers optional and individual instruction in the operation of the devices. Soyer also 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.

  • Page 8: Important Safety Instructions

    Do not touch or open, danger to unauthorised persons. Danger to persons with medical implants such as pacemakers. The information sign is not a warning sign. It indicates important and useful information on the subject. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 9: General Safety Instructions

     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. Operating instructions Soyer Bolzenschweißtechnik...
  • Page 10 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.
  • Page 11 Always use personal protective equipment. 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. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 12: Personal Protection Equipment

    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. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 13: Intended Use Of The Stud Welding Device

    Intended use of the stud welding guns With the SOYER® stud welding guns, pins and threaded studs from M3 to M8 (up to M10 with special gun and adapter) 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).

  • Page 14: Operating Company Prerequisites

    This work must be performed in accordance with the applicable technical rules for electrotechnical devices. All devices of Soyer Bolzenschweißtechnik GmbH must only be opened by personnel of Soyer or by personnel authorised by Soyer. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 15: Transport

    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. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 16: Description Of Bms-9(V) Stud Welding Devices

    M8 (M10 with special welding gun) Working method With the SOYER® BMS-9 stud welding device, pins and threaded studs from M3 to M8 (M10 with BMS-9V and special gun) as well as many different weld fasteners made of steel or stainless steel can be welded in accordance with DIN EN ISO 13918 (capacitor discharge).

  • Page 17: Capacitor Discharge Stud Welding

    6.2.2 Capacitor discharge stud welding The SOYER® BMS-9 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 Stud tip is placed into...

  • Page 18: Overview Of The Controls

    19. Function key to increase the displayed charging voltage Display Mains cable Socket for the connection of the earth cable 7-pin connection socket for the control cable Socket for the connection of the welding cable Operating instructions Soyer Bolzenschweißtechnik...

  • Page 19: Displaying The Operating States

    LED lights up when the release button on the welding gun is pressed. Malfunction The LED lights up when a malfunction of the stud welding device occurs. See chapter "12.5 Malfunctions with an error message" on page 50. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 20: Technical Data For Bms-9(V) Stud Welding Device

    Technical data for BMS-9(V) stud welding device Designation BMS-9 / BMS-9 V stud welding device Welding process Capacitor discharge stud welding Standard gun PS-9 Welding area M3 - M8 or Ø 3 - 8 mm for steel, stainless steel, aluminium and brass (M8 or Ø 8 in aluminium and...

  • Page 21: Permitted Stud Welding Guns

    Hazards for the operator may occur when a wrong welding gun is used.  Only use welding guns hereinafter permitted by Soyer. The use of other guns or guns from another manufacturer will invalidate the declarations of conformity and the warranties of Soyer.

  • Page 22: Cleaning Of The Stud Welding Device

    Improper cleaning may cause damage to the device.  Make sure that no liquids get into the device.  Do not use aggressive detergents for cleaning the device. The frequency of cleaning depends on the operating conditions of the stud welding device. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 23: Description Of The Ps-9 And Ps-9K Stud Welding Guns

    Support tube Release button Power and control cable for connection to the stud welding device The PS-9 and PS-9K stud welding guns may only be operated with the stud welding devices specified in the technical data. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 24: Type Differentiation

    The height of the lift is also crucial for the weld result. The lift height can be determined using the lift time with the aid of the BMS-9(V) stud welding device. To do so, observe chapter "11.1.3 Setting the lift time (height of lift) in the "Setup" mode" on page 42.

  • Page 25: Technical Data For Ps-9(K) Stud Welding Guns

    • Adjustable stud chuck up to a maximum of 35 mm Longer stud lengths possible with special accessories. Stud welding devices The gun is approved for operation on the following SOYER® stud welding devices: • BMS-9 • BMS-9V • PS-9: 2.7 kg including cable Weight •...

  • Page 26: Cleaning Of The Stud Welding Gun

    Welding spatters and slag can be sharp-edged.  Wear protective gloves when cleaning. We recommend the use of SOYER® separating spray in order to prevent impurities from welding spatters and slag and to simplify the cleaning process. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 27: Description Of The Ps-1K Stud Welding Gun

    Due to a projection on the support tube and a spring in the gun, the stud of this gun is pressed firmly to the workpiece (contact gun). The stud is not lifted before welding. The PS-1K stud welding gun may only be operated with the stud welding devices specified in the technical data. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 28: Technical Data For Ps-1K Stud Welding Gun

    Adjustable stud up to a maximum of 35 mm. Longer stud lengths possible with special accessories Stud welding devices The gun is approved for operation on the following SOYER® stud welding devices: • BMS-6 ISO • BMS-8N • BMS-8NV • BMS-9 (*) •...

  • Page 29: Cleaning Of The Stud Welding Gun

    Welding spatters and slag can be sharp-edged.  Wear protective gloves when cleaning. We recommend the use of SOYER® separating spray in order to prevent impurities from welding spatters and slag and to simplify the cleaning process. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 30: Description Of The Stud Chuck

    Non-adjustable stud chucks, as opposed to adjustable stud chucks, do not have to be set to the length of the weld stud. Some SOYER® welding guns can be operated with non-adjustable stud chucks. Correct application and triggering of the stud welding gun with weld stud is monitored by a safety switch in the stud welding gun.
  • Page 31 Step 6: Slide the stud chuck up to the stop into the spring piston of the gun. Step 7: Hand-tighten the union nut. Step 8: Plug the support tube onto the gun. The assembly is complete. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 32: Adjusting And Installing Adjustable Stud Chucks

    Insert the stud into the stud chuck. Step 3: Adjust the stop screw so that the top of the flange of the stud sits between 1.5 mm and 3 mm above the stud chuck when it touches the screw. Operating instructions Soyer Bolzenschweißtechnik...
  • Page 33 Remove the gun support tube. It is not mandatory to remove the support tube, however this makes use easier. Step 4: Undo the union nut Step 5: If there is still a stud chuck in the gun, remove it. Operating instructions Soyer Bolzenschweißtechnik...
  • Page 34 The stud/stud flange must protrude 1.5 – 3 mm from the support tube. If applicable, correct the setting of the stud chuck (see chapter "Adjusting the stud chuck" on page 32). The assembly is complete. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 35: Setup And Connection

    The installation location for the stud welding device must be clean and dry. Observe the permissible temperatures in chapter "6.4 Technical data for BMS-9(V) stud welding device" on page 20. Ensure that ventilation for the stud welding device is sufficient. Do not install the stud welding device in an unventilated room.

  • Page 36: Connection Of The Stud Welding Device And The Stud Welding Guns

    10.2.1 Mains connection After installation, connect the stud welding device to the power supply using the mains plug. See chapter "6.4 Technical data for BMS-9(V) stud welding device" on page 20. 10.2.2 Connecting the earth cable A secure earth connection must be established between the workpiece onto which the studs are welded and the stud welding device.
  • Page 37 Ideal condition, stud is located in the centre of the two earth connections. Asymmetrical earth connection The arc is deflected to the side where there is a lower current density. Workpiece geometry Additional workpiece masses disturb the arc symmetry. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 38: Connecting The Stud Welding Gun

    (b) and tighten the union nut. The gun type is automatically recognised by the stud welding device. Check whether the connection of the gun requires any special adapters (see chapter "6.5 Permitted stud welding guns" on page 21). Operating instructions Soyer Bolzenschweißtechnik...

  • Page 39: Settings

    This value is a reference value that has to be modified with the arrow keys when carrying out test weldings. The value adjusted with the arrow keys is saved even after switching the device off. It remains unchanged until a new value is entered. Operating instructions Soyer Bolzenschweißtechnik...
  • Page 40 Additionally, empirical values for the adjustment of the lift time can be found in the tables below (see chapter "11.1.3 Adjusting the lift time (height of lift) in the "Setup" mode" BMS-9 adjustment table / adjustment aid Device key Ø [mm] Ø3...

  • Page 41: Adjusting The Charging Voltage

    The value may be increased or decreased by pressing the arrow keys ↑↓. The charging voltage is adjusted. The set value is saved and remains unchanged after the device has been switched off and back on again. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 42: Adjusting The Lift Time (Height Of Lift) In The "Setup" Mode

    Connect the device as described in chapter "10.2 Connection of the stud welding device and the stud welding guns" on page 36. Step 2: Check that the stud welding device is switched off. Step 3: Insert a welding stud into the gun. Operating instructions Soyer Bolzenschweißtechnik...
  • Page 43 The lift time is changed using the adjustment ring on the welding gun for the height of lift of the stud. When the required lift time is set, switch off the stud welding device and then back on again. The device is then back in the operating mode. Operating instructions Soyer Bolzenschweißtechnik...
  • Page 44  If the lifting cycle is carried out without the message that the stud is on the workpiece, then [- - -] is shown instead of the lift time as there was no earth connection. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 45: Welding Operation

    Description of the PS-1K stud welding gun" on page 27 and chapter "9. Step 3: Description of the stud chuck" on page 30). Only use SOYER® welding studs. Step 4: Check the charging voltage and lift time/height of lift (see chapter "11.1 Adjusting the charging voltage and lift time on the stud welding device"...

  • Page 46: Notes On Checking The Quality Of The Weld

    The welding process is finished. 12.2 Notes on checking the quality of the weld If the SOYER® stud welding equipment is handled correctly and the correct materials are selected, the strength of the welding joint (welding zone) is always higher than the strength of the stud or the base material.
  • Page 47 The welding bead is weak and unevenly formed. Poor welding joint, e.g. due to a blow effect or a welding gun that was shaken or applied at a slant. The stud flange is not welded completely and has visible imperfections. Undercuts are visible. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 48: Switching Off The Device

    12.3 Switching off the device Switch off the stud welding device at the mains switch. The connected welding gun is switched off automatically. Ensure that the stud welding device cannot be switched on and used by unauthorised persons. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 49: Welding Defects And Their Causes

    12.4 Welding defects and their causes In the following, the most common welding errors, possible causes and troubleshooting are described. Please contact Heinz Soyer Bolzenschweißtechnik GmbH if a problem cannot be solved. Error Possible cause and troubleshooting System does not Stud welding device is not switched on.

  • Page 50: Malfunctions With An Error Message

    Danger during troubleshooting During troubleshooting, various dangers may occur.  All devices of Soyer Bolzenschweißtechnik GmbH may only be opened by personnel of Soyer or personnel authorised by Soyer.  For troubleshooting, the device must be disconnected from the main power supply and secured against accidental switch-on.
  • Page 51 • In the event of error code E05, excess temperature, the welding device cannot be used until the displayed error message disappears. • If the device operates with reduced charging current due to high internal temperatures, the "Malfunction" LED flashes. Operating instructions Soyer Bolzenschweißtechnik...

  • Page 52: Maintenance And Repair

    Tel.: 0049-8153-885-0 Fax: 0049-8153-8030 Mail: info@soyer.de Please have the serial number at hand during service requests. Alternatively, you can contact your respective Soyer agent. Contact information can be found on our website at www.soyer.de or www.soyer.com (English) 15 Warranty conditions The warranty period for commercial or equal use is 12 months.
  • Page 53 Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 82237 Wörthsee Tel.: 0049-8153-885-0 Mail: info@soyer.de www.soyer.com Operating instructions Soyer Bolzenschweißtechnik...

This manual is also suitable for:

Bms-9vPs-9Ps-9kPs-1k

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