Soyer BMS-9 ACCU Manuale utente
EN
Operating
Instructions
Stud welding device BMS-9 ACCU
Stud welding gun PS-9K ACCU
EN
Device numbers
We recommend to enter the device numbers in the list so that they can be ac-
cessed quickly if servicing is required.
Operating Instructions
Document no.: P00162, 04-2019, translation of the original instructions
(English: P00262)
All information in this document is the property of
Heinz Soyer Bolzenschweißtechnik GmbH.
Device Type Serial number
Stud welding device BMS-9 ACCU
Battery BMS-9 ACCU
Stud welding gun PS-9K ACCU
Revision status
Document created/amended Editor Date
Original Created DD 03/05/2019
Operating Instructions Soyer Bolzenschweißtechnik 3
CONTENTS
1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1. Validity of the operating instructions 5
1.2. Declarations of conformity 5
1.3. Manufacturer 7
1.4. Instruction, training 7
1.5. Standards and directives 7
2. Important safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1. Warning signs used 8
2.2. General safety instructions 9
2.3. Personal protective equipment 12
2.4. Intended use of the stud welding device 13
2.4.1 Incorrect use 13
2.5. Intended use of the stud welding guns 13
2.5.1 Incorrect use 13
2.6. Operating company prerequisites 14
2.6.1 Prerequisites for personnel 14
3. Important safety instructions for battery operation . . . . . . . . . . . . . . . . . . . . 15
4. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5. Storage, shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6. Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7. Description of the BMS-9 ACCU stud welding
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . device 19
7.1. Working method 19
7.1.1 Product features 20
7.1.2 Capacitor discharge stud welding 20
7.2. Overview of the controls 21
7.2.1 Displaying the operating states 22
7.2.2 Indication of the battery charging status on the device display 23
7.3. Charging and inserting the battery 24
7.4. Technical data of the BMS-9 ACCU stud welding device 28
7.5. Permitted stud welding guns 30
4 Operating Instructions Soyer Bolzenschweißtechnik
CONTENTS
7.6. Cleaning the stud welding device 30
8. Description of the PS-9K ACCU stud welding gun . . . . . . . . . . . . . . . . . . . . . 32
8.1. Technical data of the PS-9K ACCU stud welding gun 33
8.2. Cleaning of the stud welding gun 34
9. Description of the stud chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.1. Adjusting and inserting the adjustable stud chucks 35
10. Setup and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.1. Requirements for the installation location 39
10.2. Connection of the stud welding device and the stud welding guns 40
10.2.1 Power supply 40
10.2.2 Switching the device on and off 40
10.2.3 Connecting the earth cable 40
10.2.4 Connecting the stud welding gun 42
11. Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11.1. Adjusting the charging voltage on the stud welding device 43
12. Welding operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
12.1. Carrying out welding 45
12.2. Notes on checking the quality of the weld 46
12.2.1 Visual inspection 46
12.3. Welding defects and their causes 48
12.4. Malfunctions with an error message 49
13. Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
14. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
15. Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
General information
Operating Instructions Soyer Bolzenschweißtechnik 5
1. General information
These operating instructions include important instructions and provisions for the
operation of the devices. Please keep the operating instructions at hand near 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 device BMS-9 ACCU
Stud welding gun PS-9K ACCU
i
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
6 Operating Instructions Soyer Bolzenschweißtechnik
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
Stud welding device
Machine type
BMS
-9 ACCU
Machine no.
_____________________
Applicable EU guidelines
RoHS directive (2011/65/EU)
Low-voltage directive (2014/35/EU)
EMC directive (2014/30/EU)
Harmonised standards
applied, in particular
EN 60974
-1:2012
EN 60974
-10:2008
National regulations applied
DGUV direc
tive 1
Date
29 March 2019
Manufacturer
- signature
Function of the signatory
CEO
General information
Operating Instructions Soyer Bolzenschweißtechnik 7
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
Mail: [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://youtu.be/QrYjCVNdRZk.
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
i
Also see our video instructions at
www.youtube.com/user/SoyerGmbH.
Important safety instructions
8 Operating Instructions Soyer Bolzenschweißtechnik
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
!
i
Important safety instructions
Operating Instructions Soyer Bolzenschweißtechnik 9
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.
Important safety instructions
10 Operating Instructions Soyer Bolzenschweißtechnik
DANGER
!
Danger from electric current during maintenance and repair work
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.
The battery of battery-operated devices must be removed.
• Before performing any work on the stud welding gun, the supply cables to
the stud welding device must be disconnected.
• 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.
DANGER
!
Danger from magnetic fields
In the area surrounding the device, strong magnetic fields which may influ-
ence medical auxiliary devices and therefore result in danger to life occur
during the welding process.
• Persons with electric medical aids (e.g. pacemakers) must stay away from
the devices.
• The operating personnel must ensure that persons with medical aids stay
away from the devices.
DANGER
!
Danger of explosion from inappropriate operation sites in explosive
areas
The device is not designed for use in explosive areas.
• The device must not be installed and operated in explosive areas.
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