Soyer BMS-8N Manuel utilisateur

Operating

Instructions

Stud welding devices BMS-8N

BMS-8NV

Stud welding guns PS-1 and PS-1K

PS-3K(Stativ)

PS-0K

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

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

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

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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