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Summary of Contents for Soyer BMS-4 ACCU-DUO
- Page 1 Operating Instructions Stud welding device BMS-4 ACCU-DUO DE: English version Read these operating instructions before starting any work! Doc.ID: P00225 05.2022 www.soyer.com Date of issue:...
- Page 3 Stud welding gun PS-0DV Operating Instructions Document no.: P00225, 05-2022, translation of the original German manual (German: P00125) All inf ormation contained in this document is the property of Heinz Soyer Bolzenschweißtechnik GmbH. Revision status Document Created / Modified Editor...
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Page 4: Table Of Contents
General safety instructions ..................10 Safety instructions for the mode of operation ............. 13 Personal protective equipment ................14 Intended use of the stud welding device BMS-4 ACCU-DUO ........15 2.5.1 Incorrect use..................... 15 Requirements on the part of the operator ..............16 2.6.1... - Page 5 Welding defects and their causes ................45 11.4 Malfunctions with an error message on the welding device .......... 46 Maintenance and repair ..................47 Service ........................ 47 Warranty conditions ..................... 47 Spare parts ......................48 Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
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Page 6: General Information
The devices are designed and constructed in accordance with the generally 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 BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... - Page 7 Declaration of conformity – Stud welding device Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
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Page 8: Manufacturer
Instruction, training Soyer GmbH offers optional and individual instruction in the operation of the devices. Moreover, Soyer GmbH offers training for customer-specific use of the devices. Inf ormation on the scope and costs of instruction and training can be obtained f rom Soyer GmbH. -
Page 9: Important Safety Instructions
Do not touch or open, danger to unauthorised persons. Danger to persons with medical implants such as pacemakers. The inf ormation sign is not a warning sign. It indicates important and useful information on the relevant topic. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 10: General Safety Instructions
Starting the device with f aulty protective devices is not permitted. Faulty • protective devices must be repaired or replaced immediately. Unintentional operation by third parties must be prevented. Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... - Page 11 Danger of explosion from an inappropriate installation site in explosive atmospheres The device is not designed for use in potentially explosive zones. • The device must not be installed and operated in potentially explosive atmospheres. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
- Page 12 Fire hazard from hot welding spatter Welding spatter or hot workpieces produced during the welding process can result in f ire hazard. Do not store combustible or highly inflammable materials in the welding area. • Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
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Page 13: Safety Instructions For The Mode Of Operation
Do not look directly into the flash. • The gun carries out lif ting movements during the welding process. Do not hold the gun tight in the area of moving parts. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 14: Personal Protective Equipment
Welding spatter occurs during the welding process. Wear appropriate, non-combustible, heat-resistant saf ety footwear. Hearing protection Depending on the welding device and the welding application, relatively loud welding noises may occur. Wear appropriate hearing protection. Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 15: Intended Use Of The Stud Welding Device Bms-4 Accu-Duo
Misuse of the welding gun as a tool, e.g. as a hammer for checking the weld quality, is not permitted. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 16: Requirements On The Part Of The Operator
This work must be perf ormed in line with the applicable technical rules for electrotechnical devices. All devices of Soyer Bolzenschweißtechnik GmbH must only be opened by Soyer personnel or personnel authorised by Soyer. Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 17: Important Safety Instructions For Battery Operation
Never use or store batteries and devices with inserted battery in an explosive environment or in an environment with highly flammable substances. • Ambient temperature during operation of the device: -20 °C to +50 °C. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... - Page 18 Consult the local waste disposal company. Never dispose of batteries in household waste. • Do not dispatch batteries. If a battery is defective, please contact Soyer GmbH. • • Do not touch any leaking fluid with bare hands. Collect the fluid and dispose of it in the correct manner.
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Page 19: Transport
Any material separation must be carried out in accordance with the regulations. For the disposal of the battery, please observe chapter “3. Important safety instructions for battery operation” on page 17 ff. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 20: Description Of The Bms-4 Accu-Duo Stud Welding Device
7 Description of the BMS-4 ACCU-DUO stud welding device The main elements of the stud welding device and its f eatures are described in the f ollowing. Figure 01: BMS-4 ACCU-DUO stud welding device Item Designation BMS-4 ACCU-DUO stud welding device... -
Page 21: Working Method
Automatic storage of the charging voltage Short charging cycles to increase productivity • • Precise digital display of the charging voltage • Monitoring of all functions via a clear function display field Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 22: Capacitor Discharge Stud Welding
7.1.2 Capacitor discharge stud welding The SOYER BMS-4 ACCU-DUO stud welding device operates 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 bank to generate arc energy. -
Page 23: Overview Of The Controls
Display of operating states, see chapter “7.2.1. Displaying the operating states” on page 24 Function key for increasing displayed charging voltage Display Gun cable with PS-0DV welding gun (permanently connected) Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 24: Displaying The Operating States
You see this when you switch on the device directly after the charging voltage has been displayed (the charging voltage is displayed as a small "u" f ollowed by the voltage in volts). Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 25: Charging And Inserting The Battery
Charging and inserting the battery The BMS-4 ACCU-DUO is operated exclusively by a battery. Please ensure that the device battery is always charged and ready for operation. To charge the battery, you need the dedicated original charging device (item number F07051/FA). - Page 26 Removing, charging and inserting the battery Step 1: To remove the battery, pull the cover up to open it. Step 2: Pull out the battery. Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
- Page 27 (a) of the charging device is illuminated. Remove the battery from the charging device when it is fully charged. The charging device is not suitable as a permanent storage location for the battery. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
- Page 28 (a), the position is correct. If the battery cannot be pushed completely into the device, check the orientation and the contacts. Step 6: Close the cover. The exchange of the battery is complete. Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
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Page 29: Technical Data Of The Bms-4 Accu-Duo Stud Welding Device
Protection class IP 30 Dimensions 83 x 96 x 152 mm (w x h x d) Weight approx. 0.5 kg with mains cable Item number F07051/FA Subject to technical changes Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... - Page 30 89 x 77 x 142 mm (w x h x d) Weight approx. 1.2 kg Colour RAL 5009 azure Item number F07016/FA Subject to technical changes Please also observe chapter “3. Important safety instructions for battery operation” on page 17 ff. Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
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Page 31: Permitted Stud Welding Guns
Make sure that no detergents get into the device. Do not use aggressive detergents for cleaning the device. • The f requency of cleaning depends on the operating conditions of the stud welding device. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 32: Description Of The Ps-0Dv Stud Welding Gun
(contact gun). The weld studs are not lifted before welding. The PS-0DV stud welding gun may only be operated with the stud welding devices specified in the technical data. Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 33: Technical Data Of The Ps-0Dv Stud Welding Gun
Wear protective gloves when cleaning. We recommend the use of SOYER ® separating spray (order number M01464) in order to prevent impurities from welding spatter and slag and to simplify the cleaning process. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 34: Description Of The Stud Chuck
To attach heat cost allocators, two capacitor welding studs with M3 thread are usually welded on. Please ensure that you follow the installation instructions and specifications of the respective heat cost allocator manufacturers. Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 35: Installation Of The Stud Chuck
Ensure that you always use two identical stud chucks. • The bellows (splash guard) was removed to achieve a better view. In practice, the bellows is not removed when installing or replacing the stud chucks. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 36: Setting The Stud Distance
If a distance has already been permanently set, remove both spacers or replace with another spacer, if need be. Figure 8: Stud distance is permanently set by means of two spacers. Figure 9: Without spacers. Stud distance must be adjusted. Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... - Page 37 Slightly loosen the locking screws (a). Bellows not pictured Step 4: Set the required distance between 20 mm and 60 mm by sliding the working pistons (a). Bellows not pictured Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
- Page 38 Hand-tighten the fastening screws (b) again. The assembly is complete. The bellows (splash guard) was partly removed to achieve a better view. In practice, the bellows is not removed when adjusting the stud distance. Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
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Page 39: Setup And Connection
Mobile use is not permissible. Danger from welding vapours Hazardous fumes may occur, depending on the material of the workpiece and/or the welding stud. • Ensure suitable suction of welding vapours, if necessary. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 40: Connection Of The Stud Welding Device
10.2 Connection of the stud welding device 10.2.1 Power supply The BMS-4 ACCU-DUO stud welding device is operated exclusively by a battery. To use the battery, please observe chapter “7.3. Charging and inserting the battery” on page 25 f f. - Page 41 ↑↓ to increase or decrease the value, if required. The charging voltage is adjusted. The set value is saved and retained even after the unit is switched off and on again. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
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Page 42: Welding Operation
Check the charging voltage (see chapter “10.4. Adjusting the charging voltage on the stud welding device” on page 40). Step 4: Ensure that the welding points on the radiator are metallically bright. Grind welding points if need be. Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... - Page 43 Figure 10: Example - Welding process at a radiator Please ensure that you follow the installation instructions and specifications of the respective manufacturers of the heat cost allocators and radiators. Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
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Page 44: Notes On Checking The Quality Of The Weld
Poor weld joint, e.g. due to a blow effect or a welding gun that was shaken or applied at a slant. The stud f lange is not f ully welded and has visible imperf ections. Undercuts are visible. Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... -
Page 45: Welding Defects And Their Causes
11.3 Welding defects and their causes The f ollowing describes the most common welding faults, their possible causes and how to eliminate them. Please contact Heinz Soyer Bolzenschweißtechnik GmbH if a problem cannot be solved. Error Possible cause and troubleshooting Device does not Stud welding device is not switched on or battery is empty. -
Page 46: Malfunctions With An Error Message On The Welding Device
11.4 Malfunctions with an error message on the welding device Dangers during troubleshooting During troubleshooting, various dangers may occur. All devices of Soyer Bolzenschweißtechnik GmbH must only be opened by • personnel of Soyer or personnel authorised by Soyer. •... -
Page 47: Maintenance And Repair
Phone: 0049-8153-885-0 Fax: 0049-8153-8030 Email: info@soyer.de Please have the serial number ready during service requests. Alternatively, you can also contact your respective Soyer agent. Contact information can be f ound on our website at www.soyer.de or www.soyer.com (English) 14 Warranty conditions The warranty period for commercial or equal use is 12 months. -
Page 48: Spare Parts
Socket wrench SW 14/17 M01444 Bellows F04671 Protective plate/ F04671 wiper Spacer 32 mm F04928 40 mm F04929 50 mm F04930 52 mm F04931 57 mm F04932 Battery F07016/F Battery charger F07051/F Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik... - Page 49 Operating i n structions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
- Page 50 Operating instructions BMS-4 ACCU-DUO | Heinz Soyer Bolzenschweißtechnik...
- Page 52 Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14 82237 Wörthsee Tel.: 0049-8153-885-0 Mail: inf o@soyer.de www.soyer.de...
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