Related Manuals for Soyer BMS-8N
Summary of Contents for Soyer BMS-8N
- Page 1 Operating Instructions Stud welding devices BMS-8N BMS-8NV Stud welding guns PS-1 and PS-1K PS-3K(Stativ) PS-0K...
- Page 2 PS-1K PS-3K PS-3K Stativ PS-0K 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. Revision status Document created/amended Editor Date Original Created 2 October 2018...
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Page 3: Table Of Contents
5. Disposal ............16 6. Description of BMS-8N(V) stud welding devices ..... . 17 6.1. - Page 4 14. Welding operation ..........49 14.1. Carrying out welding 14.2. Notes on checking the quality of the weld 14.2.1 Visual inspection Operating Instructions Soyer Bolzenschweißtechnik...
- Page 5 17. Warranty conditions ..........57 Operating Instructions Soyer Bolzenschweißtechnik...
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Page 6: 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 7 RoHS directive (2011/65/EU) Low- Applicable EU guidelines voltage directive (2014/35/EU) EMC directive (2014/30/EU) EN 60974-1:2012 Harmonised standards EN 60974-10:2008 applied, in particular DGUV directive 1 National regulations applied Date 16 July 2015 Manufacturer - signature Function of the signatory Operating Instructions Soyer Bolzenschweißtechnik...
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Page 8: Manufacturer
Fax: 0049-8153-8030 Email: info@soyer.de 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. -
Page 9: Important Safety Instructions
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. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 10: 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 11 • 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 12 WARNING 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...
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Page 13: Personal Protective 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 14: Intended Use Of The Stud Welding Device
2.5 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 15: Operating Company Prerequisites
This work must be performed in accordance with the applicable tech- personnel nical rules for electrotechnical devices. All devices of Soyer Bolzenschweißtechnik GmbH must only be opened by personnel of Soyer or personnel authorised by Soyer. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 16: 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 17: Description Of Bms-8N(V) Stud Welding Devices
The main elements of the stud welding device and its features are described in the following. 6.1 Type differentiation The difference between the device types BMS-8N and BMS-8NV described in this instruction lies in the different performances of the capacitor banks and therefore in the welding performance. - Page 18 The piece. and the metal sheet. material solidifies and the stud is permanently welded. For more information on this subject, please visit: www.soyer.com. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 19: Overview Of The Controls
Description of BMS-8N(V) stud welding devices 6.3 Overview of the controls Figure 1: Overview of the front panel Item Designation Up arrow key to increase the charging voltage or the stud diameter (depending on the display settings). Display for showing the charging voltage or the stud diameter. - Page 20 Description of BMS-8N(V) stud welding devices Figure 2: Overview of the back panel Item Designation Mains switch for turning the device on/off. Fuses Type plate Mains plug Operating Instructions Soyer Bolzenschweißtechnik...
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Page 21: Support Table Stud Diameter/Charging Voltage
Description of BMS-8N(V) stud welding devices 6.3.1 Support table stud diameter/charging voltage Ø 3 Ø 4 Ø 5 Ø 6 Ø 7 Ø 8 Figure 3: Support table on the front panel Item Designation Row of stud diameters in [mm]. -
Page 22: Displaying The Operating States
Description of BMS-8N(V) stud welding devices 6.3.2 Displaying the operating states Figure 4: Operating states Item Designation Ready In normal operation, the LED lights up when the stud welding device is ready for operation in normal mode. Stud on workpiece The LED lights up when the earth terminal is connected and the stud touches the workpiece. -
Page 23: Technical Data On Bms-8N(V) Stud Welding Device
Description of BMS-8N(V) stud welding devices 6.4 Technical data on BMS-8N(V) stud welding device Designation BMS-8N / BMS-8NV stud welding device Welding Capacitor discharge stud welding procedure Standard gun PS-1K Welding area M3 - M8 or Ø 3 - 8 mm for steel, stainless steel, aluminium and brass (M8 or Ø... -
Page 24: 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 warranties of Soyer. -
Page 25: Cleaning The Stud Welding Device
Description of BMS-8N(V) stud welding devices 6.6 Cleaning the stud welding device DANGER Dangers during cleaning Improper cleaning of the stud welding device can endanger personnel. • The device may only be cleaned by trained specialists. • Before any cleaning work is done, the stud welding device must be discon- nected from the main power supply and secured against accidental switch- •... -
Page 26: Description Of Ps-0K 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-0K stud welding gun may only be operated with the stud welding devices specified in the technical data. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 27: Technical Data For The Ps-0K Stud Welding Gun
M3 - M8 Stud chuck Adjustable Stud length Adjustable stud chuck up to a maximum of 35 mm Stud welding devices The gun is approved for operation on the following SOYER® stud welding devices: • BMS-6 ISO • BMS-8N • BMS-8NV •... -
Page 28: 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 29: Description Of The Ps-1 Stud Welding Gun
The spring pressure is adjustable in order to ensure optimal welding re- sults. The stud is not lifted before welding. The PS-1 stud welding gun may only be operated with the stud welding devices specified in the technical data. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 30: Technical Data For The Ps-1 Stud Welding Gun
Stud length Adjustable stud chuck up to a maximum of 35 mm Longer stud lengths with optional accessory possible Stud welding devices The gun is approved for operation on the following SOYER® stud welding devices: • BMS-6 ISO • BMS-8N •... -
Page 31: 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 32: 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 33: Technical Data For The Ps-1K Stud Welding Gun
Stud length Adjustable stud chuck up to a maximum of 35 mm Longer stud lengths with optional accessory possible Stud welding devices The gun is approved for operation with the following SOYER® stud welding devices: • BMS-6 ISO • BMS-8N •... -
Page 34: 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 35: Description Of The Ps-3K And Ps-3K Stativ Stud Welding Guns
PS-3K stud welding gun with support Due to a projection on the gun legs 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. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 36: Technical Data For The Ps-3K (Stativ) Stud Welding Gun
Longer stud lengths with optional accessory possible PS-3K Stativ: Stud length up to 60 mm, without optional accessory. Stud welding devices The gun is approved for operation on the following SOYER® stud welding devices: • BMS-6 ISO • BMS-8N •... -
Page 37: 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 38: Description Of The Stud Chuck
Adjusting the Adjusting an adjustable stud chuck stud chuck Step 1: Select the stud chuck according to the required stud diameter. Step 2: Insert the stud into the stud chuck. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 39: Installing The Stud Chuck (Gun Without Support)
Switch off the stud welding device when the gun is con- nected to it. Step 2: Set the stud chuck to the required stud. Step 3: Remove the gun support tube. It is not mandatory to remove the support tube, however this makes use easier. Operating Instructions Soyer Bolzenschweißtechnik... - Page 40 If there is still a stud chuck in the gun, remove it. 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. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 41: Installing The Stud Chuck (Gun With Support)
Set the stud chuck to the required stud. Step 3: Undo the clamping screws of the support. Step 4: Undo the union nut (a). If there is still a stud chuck (b) in the gun, remove it. Operating Instructions Soyer Bolzenschweißtechnik... - Page 42 1.5 - 3 mm from the support tube. If applicable, correct the settings of the stud chuck by moving the support. After adjusting the stud protrusion, tighten the clamp screws of the sup- port. The assembly is complete. Operating Instructions Soyer Bolzenschweißtechnik...
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Page 43: Setup And Connection
12.1 Requirements for the installation location The installation location for the stud welding device must be clean and dry. Ob- serve the permissible temperatures in chapter “6.4 Technical data on BMS-8N(V) stud welding device” on page 23. Ensure that ventilation for the stud welding de- vice is sufficient. -
Page 44: Connection Of The Stud Welding Device And The Stud Welding Guns
12.2 Connection of the stud welding device and the stud welding guns 12.2.1 Mains connection After installation, connect the stud welding device to power supply using the mains plug. See chapter “6.4 Technical data on BMS-8N(V) stud welding device” on page 23. 12.2.2 Connecting the earth cable... - Page 45 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...
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Page 46: Connecting The Stud Welding Gun
(a) and turn the plug to the right up to the stop. Plug the control cable into the control cable socket (b). yer Bolzenschweißtechnik GmbH · Etterschlag · Inninger Str. 14 · 82237 Wörthsee · Tel.: 0 81 53/885-0 Operating Instructions Soyer Bolzenschweißtechnik... -
Page 47: Settings
Ø 7 Ø 8 The charging voltage is fixed to the stud diam- eter and cannot be changed when displaying the stud diameter. Switch to the display of the charging voltage to precisely adjust the charging voltage. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 48: Switching The Display
A fix charging voltage is assigned to every stud diameter (see table on the front panel). The charging voltage is adjusted. The adjusted value is saved and remains unchanged even after switching the device off and back on again. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 49: Welding Operation
Insert the appropriate stud chuck and a welding stud (see the descriptions of the stud welding guns and chapter “11. Descrip- tion of the stud chuck” on page 38). Only use SOYER® welding studs. Step 4: Check the charging voltage (see chapter “13.1 Adjusting the charging voltage on the stud welding device”... -
Page 50: Notes On Checking The Quality Of The Weld
The welding process is finished. 14.2 Notes on checking the quality of the weld If the SOYER® stud welding equipment is handled correctly and the correct ma- terials are selected, the strength of the welding joint (welding zone) is always higher than the strength of the stud or the base material. - Page 51 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...
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Page 52: Switching Off The Device
14.3 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 can- not be switched on and used by unau- thorised persons. Operating Instructions Soyer Bolzenschweißtechnik... -
Page 53: Welding Defects And Their Causes
Welding operation 14.4 Welding defects and their causes In the following, the most common welding errors, possible causes and trouble- shooting are described. Please contact Heinz Soyer Bolzenschweißtechnik GmbH if a problem cannot be solved. Error Possible cause and troubleshooting Device does not weld, no Stud welding device is not switched on. -
Page 54: Malfunctions With An Error Message
Dangers 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 55 • Wrong adapter on the gun cable • Software or hardware error (troubleshooting can only done by Soyer customer service). Notes on error messages • In case of errors E01 to E04 and E06, the device switches to malfunction. Welding is no longer possible. The device can only be recommissioned when it is switched off and then switched on again.
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Page 56: Maintenance And Repair
Maintenance and repair 15. Maintenance and repair Maintenance and repair of the stud welding device and the stud welding gun must only be performed by Heinz Soyer Bolzenschweißtechnik GmbH or authorised spe- cialists. 16. Service If servicing is required, please contact: Heinz Soyer Bolzenschweißtechnik GmbH... -
Page 57: Warranty Conditions
When using welding studs from external manufacturers, we do not assume any warranty for proper function of the stud welder and the quality of the welding joint. Operating Instructions Soyer Bolzenschweißtechnik... - Page 58 Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 82237 Wörthsee Tel.: 0049-8153-885-0 Mail: info@soyer.de...
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