Operating Instructions Stud Welder BMS-10N BMS-10NV
Contents
1. Z 0051 E e Loosen setscrew by turning it anticlockwise using Allen key SW 2 Insert screw driver into the groove of the adjusting screw chapter 1 4 2 item 1 located at the rear of the stud welding pistol and adjust by turning to the left or right till the required lift is obtained Turning to the left increases the height of lift turning to the right decreases it After adjusting check the lift and correct it if necessary RS After having adjusted the lift fix it by means of the setscrew 3 Tighten setscrew 3 by turning it clockwise using Allen key SW 2 Terminate the function Lift test after having successfully adjusted the lift A 5 soyer Appendix A PS 3 Initiation Capacitor Discharge 2 Initiation 2 1 Total view The illustration below shows stud welding pistol PS 3K The indicated compo nents are only slightly different from those of stud welding pistols PS 1 PS 3 PS OK and PS 1K Stud welding pistols PS OK and PS 1K are provided with support tubes instead of pistol legs 2 e Stud welding pistols PS OK and PS 1K are not equipped with a spring pressure indicator Stud welding pistol PS 3 is equipped with a lift indicator and adjusting screw for lift instead of the spring pressure indicator chapter 2 1 item 3 and adjusting screw for spring pressure chapter 2 1 item 4 SZ05 0594 016 X 1 Sleeve nut 4 Adjusting screw for 2 Pistol leg spr2. Contents Contents 1 General tl 422 rg et ar N as ns a nn nd strich 1 1 1 1 The following should be principally observed 20 000000 ol ln 1 1 1 2 Application 000000000000 1 2 1 3 Information on the product 2000000000000 LI 1 2 1 4 Type plate 00000000000 oo 1 2 1 5 Information on the documentation 2 00 0000 1 3 1 5 1 Chapters of operating instructions 0 LI 1 3 1 5 2 Information on operating instructions eee 1 4 1 5 3 Conduct in the case of malfunctions ________ 2 0 0000 LI 1 4 1 6 Contacts and service address 2 0 0000 LI 1 4 2 Description of stud welder _ _____________ _ oo L LLIN 2 5 2 1 Tip ignition technology 0 000000 LI 2 5 2 2 Stud welder set up ______ 2 2 200o0000000 00 oo LI 2 5 2 3 Dimension 0000000000000 2 6 2 4 TechnicalData _______ 0000000000 a a a a a a a a a aa A 2 7 2 5 Block diagram 2 2 2 2 2 8 2 6 Interface _ 2 9 2 7 Alteration of supply voltage 22222 2 10 3 Safety instructions _______ _ 2 2 22 3 11 3 1 Description of reference signs in the operating instructions eee 3 11 3 2 Staff qualification and training 2222 3 12 3 3 Dangers in the case of non compliance with safety instructions eee 3 12 3 4 Safety conscious working LI 3 12 3 5 Safety instructions forthe operator user ________ 00000000 LI 3 12 3 6 The following should be observed before starting the system 0 0 0000 02000 3 13 3 7 Before starting welding 0 Lo LI 3 14 3 8 Safety precautions at installation site ee 3 14 3 9 Working with the st
3. Before starting the work carry out some experimental weldings and test them to find out the optimum adjustment Samples have to be taken during production to ensure constantly good weld ing results see DVS Guideline 0905 Part 2 Quality assurance of stud welding joints A 3 soyer Appendix A PS 3 Adjustment of stud welding pistols Capacitor Discharge 1 4 Lift stud welding pistol PS 3 Lift is the distance the stud is lifted off the workpiece during the welding process RT The adjustment of lift is only possible with stud welding pistol PS 3 combined with stud welder BMS 10N or BMS 10NV 1 4 1 Determining the lift 1 Spring piston 2 Bellows 3 Sleeve nut 4 Stud holder 5 Pistol leg 6 Welding stud 7 Workpiece Z 0050 E e Switch on stud welder Set function Lift test at the stud welder Position welding pistol with welding stud chapter 1 4 1 item 6 on workpiece chapter 1 4 1 item 7 e Press pistol switch Stud holder chapter 1 4 1 item 4 with welding stud chapter 1 4 1 item 6 is lifted off workpiece chapter 1 4 1 item 7 Depending on the respective welding task the stud should lift off the workpiece for 2 5 4mm A 4 Appendix A PS 3 Adjustment of stud welding pistols Capacitor Discharge 1 4 2 Adjusting the lift 1 Adjusting screw Minimum lift 2 Lifting scale Medium lift 3 Setscrew Maximum lift
4. Oversized fuses could either cause defects to the electrical system or a fire A Disconnect the mains plug from the power supply when replacing fuses 5 21 Initiation soyer 5 2 5 Symbols 5 22 Symbol Designation Function Electrical energy Mains switch for switching stud welder on and off Energy range control Potentiometer for controlling the energy range iele Alteration of a quantity Modifying the necessary energy value for the respective stud diameter fo oO Digital measured value display Digital display of charging voltage in volt Function key Adjustment of charging voltage to 0 000 Ut Lift adjustment to carry out the lift test Jt LED Lift LED lights up when lifting magnet of welding pistol is activated LED Ready LED lights up when stud welder is ready for operation LED Stud on LED lights up when earth pole is connected U Workpiece and the stud touches the workpiece T LED Release LED lights up when trigger switch of ae welding pistol or head is pressed Air function Air connection of stud welding pistol welding forward head with automatic operation t Air function Air connection of stud welding pistol welding backward head with automatic operation Earth Marks earth cable connectors to be connected with ea
5. Safety instructions The tool and gear wagon GW 1 is the optimum solution for installing SOYER stud welders and for properly storing welding pistols cables studs retrofit kits etc e Make sure stud welder cannot be used by unauthorized personnel e Turn energy range controller item 4 chapter 5 1 to the left till stop smallest energy value e Check welding cable and connections of the stud welder for damages such as burn off mechanical wear etc and have damaged parts replaced by SOYER customer service 3 13 2 Stopping the stud welder when welding with optional automatic operation e Close the shut off valve of the compressed air supply e Activate the pistol switch several times until the pressure in the lines drops completely Disconnect the compressed air supply connections at the rear side item 18 and 19 chapter 5 1 and at the front side item 8 and 9 chapter 5 1 e Disconnect the interface plug from the connecting socket item 14 chapter 5 1 at the rear side of the stud welder e Disconnect the plug of the universal feeder from the connecting socket at the rear side of the stud welder item 15 chapter 5 1 e Continue as described in chapter 3 13 1 3 14 The S symbol The S symbol is the symbol for welding current sources permitted for opera tion with increased electric danger The S symbol on our stud welders refers exclusively to the welding current circuit a
6. Subject to technical changes Printed in the Federal Republic of Germany EC Conformity Declaration in compliance with EC Directive on Machinery 89 392 EEC appendix IIA Producer Declaration Designation of machines Machine type Machine no Applicable EC directives Applied harmonised standards in particular Applied national standards and technical specifications in particular Date Producer s signature Signer s function Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger StraBe 14 D 82237 Worthsee We herewith declare that the machines described in the following and the versions available on the market correspond in their design and construction to the fundamental safety and health requirements stipulated by EC Directive on Machinery Any modification of this machine without confirmation shall auto matically annul this declaration Stud Welders with tip ignition BMS 10N BMS 10NV 148 EC Directive on Machinery 89 392 EEC in the version 91 368 EEC EC Directive on Low Voltage 73 23 EEC EC Directive on Electromagnetic Compatibility 89 336 EEC in the version 93 31 EEC EN 292 1 and EN 292 2 EN 60 204 1 EN 60 974 1 VBG 1 VBG 5 VDE 0544 J anuary 1 1995 Technical Mana WFT d A i amp j 5 Ue OIE TZ it AD WU WG F gt Ei u GE 4 97 Op I A VB LA I rT ji 7 j a Deutscher A IM p 2 at Z 4 IE
7. 1 0 0 0 solder coated or galvanized max 30 u CrNi steels austenitic 2 1 2 0 0 0 CuZn 37 CuZn 30 Ms 63 70 without lead 2 2 I i 2 g Copper 2 2 1 0 0 0 AI 99 99 5 0 0 0 1 1 1 AIMg 3 AlMg 5 0 0 0 1 1 1 AIMgMn AlMgSi 0 5 AlMgSi 1 0 0 0 2 1 1 AISi5 1 well suited 2 sufficiently suited depending on requirements 0 not suited Z 0049 E Operation 6 Operation The measures mentioned in the Initiation of stud welder chapter have already been performed AA The applicable accident prevention and safety regulations in chapter 3 have to be complied with when operating the stud welder IN MORTAL DANGER Never touch the stud or stud holder during the welding process These components are current carrying e Select the energy range according to stud diameters and welding para meters chapter 5 5 by using the energy range controller item 4 chapter 5 1 LED Ready lights up item 7 2 chapter 5 2 2 Position pistol with welding stud on the workpiece Besides LED Ready item 7 2 chapter 5 2 2 LED Stud on Workpiece lights up item 7 3 chapter 5 2 2 when earth has been properly connected to the workpiece Electric circuit is completed Activate pistol switch LED Release item 7 4 chapter 5 2 2 lights up and welding process is started Charging voltage returns to 0 LED Stud on workpiece item 7 3 chapter 5 2 2 lights up LED Ready item 7 2 c
8. A 2 1 3 Adjustment of spring pressure does not apply to stud welding pistol PS 3 ___________ A 3 i Lift stud welding pistolPS 3 0202000000000 0 Lo LL LI A 4 1 4 1 Determining the lift oo LI A 4 1 4 2 Adjusting the lift 2020200000000 oo LLL A 5 2 Initiation __ A 6 2 1 Total view 0 000000 0 A 6 2 2 Connecting the stud welding pistols to the stud welder eee A 7 2 3 Operation 8 es eo ee ee ed A 7 3 Spare parts __ _ Z LLLLLLLN A 8 3 1 Spare parts list for stud welding pistol PS 3 eee A 8 3 2 Exploded view of stud welding pistol PS 3 A 9 General 1 General 1 1 The following should be principally observed With this stud welder you have purchased a product which is state of the art technology fully complies with the current safety requirements and enables successful working Before installing the stud welder always observe the following Store the operating instructions in a place accessible to every operator Ensure that the respective operator has read and understood the operating instructions prior to installation Each operator should confirm this per signature Prevent the stud welder being operated by unauthorized personnel Only trained personnel may operate the stud welder IN MORTAL DANGER Persons with pacemakers must not operate the stud welder and must not Stay in the vicinity ofthe stud welder while it is running Ensure that the stud welder is not operated near electronically sensitive li
9. nents it should be ensured however that transport is free from vibrations The stud welders BMS 10N and BMS 10NV have two handles at the side for transport and mobile use within short distances RT These carrying handles are intended for transport by hand only Never pull ropes through these handles to lift the system by crane to the installation site The system would become unstable and might tilt from its original position As a result the handles could rip and the system fall on the ground A DANGER TO HEALTH Prevent unauthorized use of the stud welding system by children and unqualified personnel RS After long system standstill we recommend having the stud welder checked by a SOYER serviceman prior to initiation 10 35 List of standards and guidelines 11 List of standards and guidelines 11 36 e 91 368 EEC formerly 89 392 EEC 73 23 EEC 93 31 EEC formerly 89 336 EEC EN 292 1 EN 292 2 EN 60204 1 formerly VDE 0113 EN 60974 1 EN 292 2 VDE 0544 VGB 1 VBG 5 DIN 4100 DIN 267 part 5 DIN 17100 DIN 8563 part 10 DIN 32500 part 3 DIN 50049 DIN 50125 DIN 54111 part 1 DVS Leaflet 0902 DVS Guideline 0905 part 1 EC Directive on Machinery EC Directive on Low Voltage EC Directive on Electromagnetic Compatibility Safety of machinery basic terms general principles of construction basic terminology systems engineering Technical prin
10. table can bear its weight Make sure mains socket and stud welder are properly earthed Comply with fire prevention regulations and do not weld in hazardous locations Make sure room is well ventilated or extract welding fumes if necessary A DANGER TO HEALTH When welding fumes and suspended matters may be generated Beware of fumes detrimental to health particularly when using surface treated materials If possible only weld in rooms which are higher than 3 m As per VBG 15 special regulations are applicable for narrow rooms 3 9 Working with the stud welder Comply with all accident prevention regulations which apply to the operation of your stud welder LS One of the accident prevention regulations applicable for stud welders is VBG 15 Welding cutting and similar working methods For more information contact the Employer s Liability Insurance Association IN MORTAL DANGER When welding do not wear clothes soiled with easily combustible substances such as oil grease and paraffin oil etc 3 14 Safety instructions If an accident happens e switch off the stud welder and disconnect it from the mains supply e calla doctor 3 10 Safety instructions for maintenance inspection and assembly works Only carry out maintenance works when stud welder has been switched off The operator must ensure that all maintenance inspection and assembly works are only carried out by au
11. 074 28 4 Hexagon nut M4 M01012 29 2 J oining piece QM 1 8 M01289 30 2 Pin and socket connector straight M01060 31 2 Angular joining piece 1 8 PU 3 M01058 32 2 Hexagon nut M4 M01012 33 2 Spring ring M4 M01074 34 1 Mains filter E03541 35 3 Binder with flange E02651 36 2 Spacing bolt M3x18 M01705 37 1 Covering plate E02659 13 44 7 Q v a WN 10N stud welder View D and E 13 8 Exploded view of BMS SZ 0169 X 13 45 Spare parts soyer 13 9 Spare parts list for BMS 10N stud welder View F 13 46 Item No Quantity RPRPrPrFrFOOORrNRFPHFENFNNNFNNFPRPNEXBFNFPRPRRPBRPRRPR RP BRP RP RR RP BRHReE HH Description Hexagon nut M4 Spring ring M4 PC Board STA 31 Distance sleeve 7x1 4x10mm Distance sleeve 7x1 4x7mm Mounting plate Fastening set Complete flat cable see item 27 A Toroidal core Mounting base self adhesive Hexagon nut M4 Spring ring M4 Washer M4 Front panel with foil Mounting base self adhesive Main switch Flat head screw M4x16 Complete turning knob comprising Turning knob Nut cover Front cap Earth connector Earth socket Pin and socket connector straight Fine wire fuse 0 1AT Fine wire fuse LOAT Locking screw Coupler socket KD 1 8 Copper plate Hexagon nut M8 Spring ring M8 Washer M8 Connecting cable Thyristor clamping cap Thyristor SAE4A not illustrated Diode 470 POA40 not illustrated Hexagon head cap screw M8x16 M
12. 10N and BMS 10NV For information regarding the stud welding pistols to be used as well as their adjustment and the universal vibrator UVR 250S please refer to the respective operating instructions of the stud welding pistols or the universal vibrator UVR 250S 2 5 soyer Description of stud welder 2 3 Dimension The stud welders BMS 10N and BMS 10NV have a robust handy and compact design and identical dimensions 400 oa soyer BMS 10N fa N N G aa Y Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger Str 14 82237 W rthsee Tel 08153 885 0 Depth 380 mm SZ 0045 E 2 6 Description ofstud welder 2 4 Technical data Designation BMS 10N BMS 10NV Welding range Like stud welder BMS 10N but steel studs up to M10 M3 M8or 2 8 mm with steel and stainless steel M3 M8o0rg 2 8mm with aluminium and brass depending on requirements Welding process Tip ignition as per DVS Leaflet 0903 with gap and contact welding Standard pistol Stud welding pistol PS 3 Current source Capacitor battery Charging capacity 88 000 uF 132 000 uF Charging voltage 50 200 V infinitely variable up down Welding time 0 001 0 003 sec Welding sequence up to 20 studs min depending on stud diameter Power supply 220 230 V 50 60 Hz 10 AT 10 Speci
13. 10NV are universally applicable for both manual and automatic operation They offer optional simple and low cost retrofitting of an automatic module for semi and fully automatic stud feed Operation is very simple because of the infinitely variable bidirectional regula tion of the charging voltage The performance values can be taken from the precise digital display located on the clearly arranged raised front panel All functions can be monitored via clearly visible pilot lamps The stud welders BMS 10N and BMS 10NV allow you to carry out function tests without welding current for welding pistols and heads lift test and to adjust the lift At the rear side of the stud welder a welding quantity counter is installed to record the welding quantities The standard CNC interface allows a problem free connection of the stud welder to bench welders Short charging cycles and high reserve capacities guarantee the readiness for operating at short intervals and enable short welding sequences soyer Initiation 5 2 1 Operating elements e Main switch item 2 chapter 5 1 The main switch is used to switch the stud welder on and off Energy range controller item 4 chapter 5 1 The energy range controller enables infinitely variable energy adjustment for weldable stud diameters Function key for adjusting the lift item 6 chapter 5 1 For carrying out the lift test on the welding pistol or welding head the charging voltage has to be s
14. 267 the cause of trouble must be determined and the test repeated again Maintenance 8 Maintenance 8 1 Stud welder The stud welders are constructed in such a way that only a minimum of maintenance is required The interior ofthe stud welders should however be cleaned by a specialist at regular intervals depending on the environmental conditions at the location of use Any defects of the system s control part can easily be eliminated by replacing the printed circuit and or the clearly arranged fuses A MORTAL DANGER Before replacing any components disconnect the mains cable from the mains supply Electric and electronic components may only be replaced by a specialist Contact the SOYER service department if necessary A DANGER TO HEALTH Before starting repair works disconnect the mains cable from the power supply and the compressed air supply from the stud welder connections Unscrew recessed head screws at both side parts Remove upper part of the housing by lifting it vertically from the unit please pay attention to the earth connection Blow through the interior of the stud welder using clean dry and filtered compressed air with a pressure of about 2 bar If no compressed air is available a vacuum cleaner may be used instead Ensure however that no components are damaged by the nozzle Replace the cover and secure it using the recessed head screws please pay attention to the earth connecti
15. Operating Instructions Stud Welder BMS 10N BMS 10NV soyer Operating Instructions C Stud Welder BMS 10N BMS 10NV Serial number Stud welder BMS 10N 148 Serial number Stud welder BMS 10NV 148 Please mark your type of stud welder with a cross and enter the serial number so that these data are available if you need service support Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger StraBe 14 D 82237 W rthsee Phone 49 0 81 53 8 85 0 Fax 49 0 81 53 80 30 E Mail verkauf soyer de export soyer de soyer Date of issue 01 12 1995 SOYER is a registered trade mark of Heinz Soyer Bolzenschwei technik GmbH It is prohibited to transmit or reprint this document as well as to utilize or disclose its contents unless this has been expressly granted Non compliance with this regulation is liable to compensation All rights reserved particularly in the case of a patent grant or GM registration We have verified that the contents of this pamphlet correspond to the hard and software described Deviations however cannot be excluded so that we cannot warrant for absolute compliance The data in this documenta tion however have been verified regularly and necessary corrections will be incorporated in future impressions We appreciate any suggestions for improvement Heinz Soyer Bolzenschwei technik GmbH 1995 All rights reserved
16. S 10N stud welder Overview 13 38 Item No Quantity Au BWN FE 22 22 22 1 2 4 Description Cap PVC grey Fillister head screw M 4x10 U washer M4 nylon Upper part of housing of BMS 10N Handle Tooth lock washer M8 Order No M01251 M01254 M01251 01 F03598 M01240 M01224 7 Q v a WN Overview 13 2 Exploded view of BMS 10N stud welder SZ 0166 X 13 39 Spare parts soyer 13 3 Spare parts list for BMS 10N stud welder View A 13 40 Item No Quantity OONADUBWNE rm he NrPBHBPHRPRBNBRRPBRBNRPNPRPRPRPRPRRB BPP RPRPRPFNDNDUWOABNNNNNN Description Threaded rod M4x140mm Spring ring M4 Hexagon nut M4 Spacing bolt M4x10 Resistor covering plate Flat head screw M4x8 Distance sleeve 7x15 Distance sleeve 07x10 Wire resistor 7 5R 100W Wire resistor 15R 100W Resistor mounting plate Hexagon nut M4 Cheese head screw M5x50 Spring ring M5 Washer M5 Washer special size M6 Toroidal mains transformer BV 47718 Hexagon nut M4 Spring ring M4 Connecting cable for pulse counter Complete flat cable 26 pole Fine wire fuse LOAT Fine wire fuse 1 6AT Fine wire fuse 3 15 AT PC Board STA 41 Hexagon nut M4 Complete flat cable Spacing bolt M4 x15 Hexagon nut M4 Spring ring M4 Transformer mounting plate Insulating disk for transformer Hexagon nut M4 Threaded rod M4x140mm Insulating plastic tube 65mm PVC hose black Hexagon nut M4 Lower part of hou
17. The adjustment of lift is only possible for stud welding pistols or welding heads with magnet e g PS 3 PS 3A The lift on the stud welding pistol or welding head is adjusted as follows e e e Switch on main switch item 2 chapter 5 1 Press function key Lift adjustment item 6 chapter 5 1 The LED Lift item 7 1 chapter 5 2 2 lights up Charging voltage returns to 9 Position pistol on workpiece Press pistol switch Stud holder lifts off the workpiece and lift can be ad justed To protect the magnet the lift test is only carried out for 1 5 secs The measure of the lift adjustment must be determined in welding tests The welding pistol has then to be adjusted accordingly For further information please refer to the respective operating instructions of the welding pistol or welding head The function Lift adjustment is terminated by pressing once again the func tion key Lift adjustment item 6 chapter 5 1 Initiation 5 5 Welding parameters The charging voltages shown in the diagram on the right are standard values They vary from the stated setting depending on the material type workpiece thickness and surface condition of the workpiece RT IMPORTANT The set welding parameters influence the reproducibility and quality of the welding results to a large extent The parameters depend on the size of the studs and the material properties The values indicated in the tab
18. __ 2 2 222 7 28 7 4 1 Standard work test 2 22O 7 28 7 4 2 Simplified worktest_ OO 7 29 7 5 Test execution 0000000 7 29 7 5 1 Production of samples __ 22O 7 29 7 5 2 Visual inspection 7 29 7 5 3 Tensile test ____ 2 2 7 29 7 5 4 Bendtest n aaa 7 30 8 Maintenance 2 3 2 Ar u ur 2 A mul nn ee De en derer 8 31 8 1 Stud welder es a en eed eae kt Ba oe ite nes 8 31 8 2 Replacement of components ee 8 31 9 Troubleshooting _ oo LLLLLLN 9 32 10 Transport and storage _ _ 2 10 35 11 List of standards and guidelines Z 2 222 11 36 12 Terms of warranty _ _ 12 37 13 Spare parts LLLLLLN 13 38 13 1 Spare parts list for BMS 10N stud welder Overview eee 13 38 13 2 Exploded view of BMS 10N stud welder Overview eee 13 39 13 3 Spare parts list for BMS 10N stud welder View A 0 13 40 13 4 Exploded view of BMS 10N stud welder View A eee 13 41 13 5 Spare parts list for BMS 10N stud welder View B and C esses 13 42 13 6 Exploded view of BMS 10N stud welder View B and C ese 13 43 13 7 Spare parts list for BMS 10N stud welder View D and E esses 13 44 13 8 Exploded view of BMS 10N stud welder View D and E 00 0 0000 0000 13 45 13 9 Spare parts list for BMS 10N stud welder View F ee 13 46 13 10 Exploded view of BMS 10N stud welder View F 13 47 soyer Contents Appendix A PS 3 Tip ignition 1 Adjustment of stud welding pistol eee A 1 1 1 Adjustment of stud holder 2222 A 1 1 2 Installation of stud holder into stud welding pistol eee
19. ains cable Washer M5 Spring ring M5 Hexagon nut M5 Hardboard Cable gland PG11 Lock nut PG11 Connecting cable Crimp lug 8 x 6 mm Order No M01012 M01074 F03616 FA M01261 M01260 E01524 M03576 F03636 FA E E03607 E01726 M01012 M01074 M01062 F03614 FA E01726 E03512 M01354 E01900 E01902 E01904 E01964 E01958 M01060 E03504 E01898 E01891 M01299 F03529 M01015 M01077 M01065 F03628 FA E E01987 E01361 E01817 M01129 E01985 M01063 M01075 M01013 F03527 E01969 E01970 F03619 FA E E02046 Spare parts 13 10 Exploded view of BMS 10N stud welder View F Z 0170 X 13 47 soyer Spare parts 13 48 Appendix A PS 3 Adjustment of stud welding pistols Capacitor Discharge Adjustment of stud welding pistol 1 1 Adjustment of stud holder The stud holders of welding pistols PS 1 PS 3K PS OK and PS 1K are all of the same type When using large studs with short type welding pistols PS OK and PS 1K however it is necessary to shorten the stop screw 4 of such welding pistols accordingly Rs For pistols PS 1 PS 3K PS OK and PS 1K use the standard stud holder with adjusting screw having a length of 40 mm Ensure that the maximum stud length does not exceed 35 mm RASS SZ06 0593 012 X 1 Stud 3 Counternut 2 Stud holder 4 Stop screw For different stud diameters different stud holders are required Adjust stud holder as fo
20. al voltage on request Fuse element at front panel 0 1 AT for main switch 10 AT for control transformer Welding cable 3 m highly flexible Earth cable 2 x 3 m highly flexible Weight 19 5 kg 20 5 kg Colour RAL 5009 azure Subject to technical changes S light deviations are possible depending on accessories e g automatic set Z 0042 E 2 7 soyer Description of stud welder 2 5 Block diagram ainpow snewony SSIeHSWU TE VLS Pueog jOAUOD m Q Tt YLS pueog jonuoD jqe gt 2 JO QUOD 104SId 109514 AOEZ GTT Aiddns Z 0067 E 2 8 Description ofstud welder 2 6 Interface BMS Stud welder Customer control CNC interface rt Oo rt bi 6 i Release Sta Sta 2 With a store programmable control which has O a transistor output please observe the polarity 7 O 3 j U external SOW SOW Ready Charge ready 5 Reload time Reload l 9 pole D Sub socket terminal strip Contact load max 24V 200mA Terminology Start Contact releases the welding process SOW Stud on workpiece Is only required when stud welder is operated via a superior control Contact is made when stud touches the workpiece e g head in fore position Ready Contact is made after the set charging voltage has been reached Reload Contact remains closed during the reload time of the stud after removal
21. amage to persons The safety instructions of this manual are marked with the general symbol for danger safety symbol in compliance with DIN 4844 W9 Warning of electric voltage is specially marked with the safety symbol in compliance with DIN 4844 W8 In addition to these symbols the words DANGER TO HEALTH or MORTAL DANGER refer to the degree of a possible danger Safety instructions the non observance of which may endanger the machine and its functions are marked with the terms CAUTION or WARNING 3 11 Safety instructions soyer General instructions are marked with the hand symbol Ike 3 2 Staff qualification and training The staff responsible for operation maintenance inspection and assembly must have the respective qualification for carrying out these works Field of responsi bility competence and the supervision of staff has to be exactly regulated by the operator If your personnel do not have the necessary knowledge they have to be trained and instructed If necessary this can be done by the manufac turer supplier on behalf of the operator Furthermore the operator must ensure that the contents of the operating instructions are fully understood by the staff The training and testing institute of welding in Munich SLV Schwei technische Lehr und Versuchsanstalt offers the appropriate training courses for your personnel 3 3 Dangers in the case of non compliance with safety instructions Th
22. ar with the operating instructions and the necessary techni cal activities training operate the system 1 5 3 Conduct in the case of malfunctions Important information if service is required If malfunctions occur first try to detect and eliminate the causes according to the list in chapter 9 Troubleshooting of our operating instructions In all other cases contact our service department If you require our service please make sure that you supply us with the following information Customer number Product designation Serial number Year of construction Options Material of stud and workpiece Stud dimensions cee o ee eo o This information will help us both to save time and unnecessary costs e g caused by delivering the wrong spare parts 1 6 Contacts and service address 1 4 If you have any questions regarding the operation of the stud welding system retrofits or if you require service please contact your responsible service office or the following address Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger StraBe 14 D 82237 W rthsee Phone 49 0 81 53 8 85 0 Fax 49 0 8153 80 30 E Mail verkauf soyer de export soyer de 7 Description ofstud welder 2 Description of stud welder 2 1 Tip ignition technology The SOYER stud welding systems run according to the principle of capacitor discharge with tip ignition as defined in DVS Leaflet 0903 German Weldin
23. ciples specifications Electric equipment of machinery general requirements Safety requirements for arc welding equip ment part 1 welding current sources Working instructions Safety requirements for arc welding equip ment General instructions instructions for accident prevention Power operated substances instructions for accident prevention Welded steel structures with predominantly dead load Screws nuts and the like technical terms of delivery testing and acceptance Constructional steels general types quality standard Quality assurance of welding works Studs for stud welding with retract ignition Certificate on material tests Testing of metallic materials tensile tests guidelines for production Non destructive method of testing Arc welding with retract ignition Quality assurance of stud welding joints Terms of warranty 12 Terms of warranty We warrant for this equipment for a period of 6 months in accordance with our conditions of sale and delivery Any claim to a warranty will be forfeited if damages are caused by improper operation or if repairs or interferences have been made by unauthorized personnel or whenever accessories and spare parts have been used which do not match our equipment We cannot guarantee the quality of welded joints if welding studs acquired from another company are used 12 37 Spare parts soyer 13 Spare parts 13 1 Spare parts list for BM
24. d M4x185mm PVC hose black Hexagon nut M4 Order No M01089 E02224 E02083 F03789 M01012 M01074 M01074 M01012 M01354 M01152 M01076 M01014 F01298 E03514 M01012 M01074 M01075 M01117 M01012 M01074 E03728 E02037 F01299 F01301 F01300 M01015 M01077 M01065 F03627 FA E F03628 FA E M01129 E01199 F03627 FA E F03628 FA E M01246 M03516 M01310 M01012 Spare parts View B and C 13 6 Exploded view of BMS 10N stud welder 13 43 soyer Spare parts 13 7 Spare parts list for BMS 10N stud welder View D and E Item No Quantity Description Order No 1 1 Back panel F03599 2 1 Complete pulse counter F03708 FA 3 1 STA 41 PCB mounting plate F03600 4 2 Spring ring M4 M01074 5 2 Hexagon nut M4 M01012 6 2 Grommet E03619 7 3 Coupler socket KD 1 8 M01299 8 1 Coupler plug KS 1 4 M01302 9 2 Flat head screw M3x16 M01349 10 1 Mounting plate F02992 11 2 Sound absorber U M5 M01284 12 1 Angular joining piece M5 PU 4 M02068 13 0 25m Pneumatic hose PU 4 M01306 14 1 Connection board M02101 15 1 Pneumatic valve M02099 16 2 Tooth lock washer M3 M01318 17 2 Hexagon nut M3 M01011 18 2 Angular joining piece M5 PU 3 M01056 19 2m Pneumatic hose SMC 4 M01067 20 1 J oining piece QM 1 4 M01290 21 1 Sound absorber U 1 8 M01285 22 1 Reducer M01538 23 1 Elbow PU 4 M03518 24 1 Pneumatic valve M02098 25 1 Pin and socket connector straight KQH 06 M02095 26 4 Washer M4 M01062 27 4 Spring ring M4 M01
25. e contact either our parent company or our field engineers 1 3 Information on the product 1 4 Type plate 1 2 Manufacturer Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger Stra e 14 D 82237 W rthsee Phone 49 0 81 53 8 85 0 Fax 49 0 8153 80 30 E Mail verkauf soyer de export soyer de Product designation Stud welder BMS 10N Stud welder BMS 10NV Country of origin Germany The type plate is located on the rear side of the stud welder It contains the following information Manufacturer s name Manufacturer s address Country of origin Product designation Method of welding Date of construction Production number Performance data Mains connection values eee ee o eo eo o General Information on the documentation The following operating instructions come with the BMS 10N and BMS 10NV stud welders e Operating instructions for stud welder BMS 10N BMS 10NV Order no P00191 For repeat orders please contact Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger StraBe 14 D 82237 W rthsee Phone 49 0 81 53 8 85 0 Fax 449 0 81 53 80 30 E Mail verkauf soyer de export soyer de 1 5 1 Chapters of operating instructions The operating instructions describe the installation and operation of the stud welder under normal conditions and comprise the following chapters in detail Chapter 1 General Information on application and product as well as supp
26. e non compliance with safety instructions may not only endanger persons but also the welding system and its environment Any non compliance with Safety instructions may result in a complete loss of damage claims Non compliance with safety instructions may have the following conse quences e Failure of important system functions Failure of prescribed methods for maintenance Danger to persons through electric mechanic thermal and acoustic influences 3 4 Safety conscious working The safety instructions listed in this manual existing national accident preven tion regulations and possible international working operating and safety regulations of the operator must be complied with 3 5 Safety instructions for the operator user 3 12 When stud welding danger may result from electric current optical radiation harmful substances smoke acoustic shock spraying sparks e o o o o Safety instructions You are therefore obliged to restrict the dangers to an inevitable degree and to pointthese dangers out to the operator and other persons involved IN MORTAL DANGER Persons with pacemakers must neither operate the stud welder nor stay near it 3 6 The following should be observed before starting the system Before starting the system pay attention to the following information e J uveniles under the age of 16 years must not operate the stud welding system Read all of the operating instructi
27. est is required is agreed upon with the customer Quality control The standard work test is restricted to the stud diameter base material and type of equipment used It comprises the following tests e Visual inspection all samples Tensile test at least 3 samples Bend test at least 3 samples In case of doubt the test scope should be extended in compliance with DVS Guideline 0905 part 2 section 5 1 1 7 4 2 Simplified work test Simplified work tests serve to check the correct setting and function of the equipment They are carried out at the beginning of every working shift and after several hours of interruption Simplified work tests include e Visual inspection all samples Bend test all samples 7 5 Test execution 7 5 1 Production of samples The studs for the work test are welded on a sheet metal the minimum size of which is 700 mm x 200 mm Use the same welding positions and edge dis tances as on the component to be welded later If it is possible and sensible from an economical point of view use parts that are identical to those used in later production 7 5 2 Visual inspection 7 5 3 Tensile test The visual inspection serves as a rough check for major defects The uniformity of the weld is assessed When in doubt tensile and bend tests should be carried out The tensile test serves to test the metallic bond of the stud with the base metal At least 3 studs are welded and then axia
28. et to 0 by pressing the function key Lift adjustment 6 5 2 2 Display elements Charging voltage display item 5 chapter 5 1 The digital display shows the adjusted energy value charging voltage in volts LED displays item 7 chapter 5 1 The LEDs show the respective operational states 7 1 7 2 7 3 i ed WE 7 1 LED Lift 7 2 LED Ready 7 3 LED Stud on Workpiece 7 4 LED Release Z 0047 E 5 2 3 Connecting elements e Mains connecting cable item 13 chapter 5 1 Use the mains connecting cable to connect the stud welder to the power supply Earth cable connectors item 12 chapter 5 1 The earth cable connectors allow the earth terminals to be connected to the stud welder e Control cable connection item 9 chapter 5 1 and welding cable socket item 10 chapter 5 1 The control cable connection and the welding cable socket serve to connect the stud welding pistol or the welding head to the stud welder 5 20 Initiation Air function forward item 8 chapter 5 1 optional Connection for welding pistols or heads with automatic stud feed Air function backward item 9 chapter 5 1 optional Connection for welding pistols or heads with automatic stud feed 5 2 4 Fuse Fuse item 1 and 3 chapter 5 1 The stud welder is protected by two fuses 0 1 AT and 10 AT A WARNING If you have to replace fuses only use those with specified electrical values
29. fe supporting equipment such as in intensive care units in hospitals WARNING Keep sufficient distance from electronic devices When stud welding highly intensive electromagnetic fields are created which may permanently damage these devices e g television sets Moreover observe the safety instructions in chapter 3 Call a doctor in case of an accident IN MORTAL DANGER The S symbol is the symbol for welding current sources permitted for operation with increased electric danger The S symbol on our stud welders refers exclusively to the welding current circuit and not to the complete stud welder 1 1 General soyer 1 2 Application The SOYER stud welder BMS 10N with tip ignition allows you to weld pins and threaded studs ranging from M3 M8 or 2 8 mm made of steel and stainless steel and M3 M8 or 2 8 mm made of aluminium and brass depending on requirements as well as a great number of various welding fasteners see chapter 2 4 Technical Data It is also possible to weld welding fasteners made of aluminium and brass The stud welder BMS 10NV with a charging capacity of 132 000 uF enables you to weld steel studs up to M10 The visual side of the workpiece is spared to a large extent from pressure marks or deformations so that even thin sheet metals under 1 mm sheet thickness retain their decorative appearance If you need advice or assistance in solving problems pleas
30. g Society This system uses the abrupt discharge of a capacitor battery to generate electric arc energy Adjusting screw Stud holder Zac I Stud Workpiece 20 Oe Z 0001 E The electric arc is initiated via the calibrated and close fit ignition tip on the welding studs and elements The stud weld base and the opposite surface of the workpiece are melted on The stud is then automatically dipped in the thin fusion zone or liquid weld pool After the immediate solidification of the mate rial an homogeneous high strength joint is produced in an extremely short welding time of only 1 3 milliseconds 0 001 0 003 sec 2 2 Stud welder set up The standard pistol to be connected to the stud welders BMS 10N and BMS 10NV is the stud welding pistol PS 3 with control cable The stud welders are optionally equipped with an automatic module for the connection of the univer sal feeder UVR 250S and for fully automatic stud feed It is necessary to use the stud welding pistol PS 3A or the welding head SK 5A when welding with automatic operation Optionally it is possible to connect the stud welding pistols PS 1 PS 1K PS OK and PS 3 as well as the welding head SK 5A These operating instructions exclusively describe the stud welders BMS
31. hapter 5 2 2 goes out Stud welder is not ready for welding Remove pistol from the workpiece All LEDs go out and the stud welder is charged to the set value After the value has been obtained LED Ready item 7 2 chapter 5 2 2 lights up and the stud welder is ready for the next welding process In the case of automatic operation one stud is reloaded Hold the pistol still during the welding process and wait until the welding process has been completed before removing it vertically from the welded stud Please also refer to the respective chapters in the operating instructions of the stud welding pistols Adjustment and installation of the stud holder into the welding pistol as well as adjustment of the welding pistol are described in the operating instructions of the stud welding pistol Quality control soyer 7 2 7 3 Quality control General The 0905 DVS Guideline part 2 of April 1979 is applicable with regard to quality assurance of stud weld joints The tests described in this section are written in simplified terms following above regulation They refer to work tests that are carried out and supervised by the user prior to and during welding Heinz Soyer Bolzenschwei technik GmbH is a member of the German Welding Society DVS Deutscher Verband fur Schwei amp technik e V Munich Demands on the company The company must employ a technical supervisor responsible for welding matters as well as qualified o
32. he edges and or rotate welding pistol Irregular operation of stud welding pistol or welding head Contact SOYER customer service Intensive sparking stud flange almost melted away Welding energy is set too high Reset welding energy using energy range controller 9 33 Troubleshooting soyer Error Cause Elimination Stud not welded with total flange surface deficient weld joint strength Welding energy set too low Reset welding energy by means of the energy range controller Poor earth connection Check earth cable and earth clamps for tight fit tighten if necessary Surface too soiled Clean workpiece surface Stud weld base deformed Use new welding studs Stud projection over stud holder incorrectly set Set projection to 2 3 mm set distance between stud holder and stud weld base Spring pressure incorrectly set Set spring pressure Welding pistol in tilted position Ensure that all 3 pistol legs are simultaneously and evenly positioned on the workpiece Stud welder switches itself off There are mains voltage fluctuations Connect stud welder directly to the current distribution Control of stud welder stud welding pistol or welding head is defective Contact SOYER customer service Transport and storage 10 Transport and storage The stud welder has a robust metal housing Owing to the electronic compo
33. ing pressure or lift 3 Spring pressure indicator stud welding pistol PS 3 or lift indicator stud welding 5 Connecting cable pistol PS 3 6 Trigger switch 7 Stud holder A 6 Appendix A PS 3 Initiation Capacitor Discharge 2 2 Connecting stud welding pistols to stud welder 2 3 Operation The stud welding pistols are connected to the stud welder by means of pistol and control cables e Connect stud welder to earth e Connect stud welding pistol as described in chapter 5 e Adjust stud welding pistol as described in Appendix A Chapter 1 e Connect stud welder to the mains supply e Adjust stud welder for the welding studs to be used e Insert welding studs into stud holder Place stud welding pistol upon workpiece and press trigger switch A 7 soyer Appendix A PS 3 Spare parts Capacitor Discharge y 3 Spare parts 3 1 Spare parts list for PS 3 stud welding pistol Spare parts list in preparation A 8 soyer 7 Appendix A PS 3 Spare parts Capacitor Discharge 3 2 Exploded view of PS 3 stud welding pistol Spare parts list in preparation A 9 soyer Appendix A PS 3 Spare parts Capacitor Discharge y A 10 Heinz Soyer Bolzenschwei technik GmbH Etterschlag Inninger Stra e 14 D 82237 W rthsee Tel 49 0 81 53 8 85 0 Fax 49 0 8153 80 30 Internet www soyer de www soyer com E Mail verkauf soyer de export soyer de
34. is welded or riveted to the metal This also includes stud welding on profile sections To ensure good welding results carry out several test welds under different conditions For example simply change the position of the earth clamps or turn the welding pistol LS Please ensure that the contact areas of the earth clamps are always kept clean and do not oxidize otherwise high transition resistances could occur that may result in a considerable reduction of the rated welding current In addition make sure that the earth clamps are clamped securely to the workpiece and the earth cables as well as the pistol cable are securely con nected to the stud welder This prevents high transition resistances and arc losses on the clamps or plug in connections which in turn would result in poor welding results Initiation soyer 5 3 2 Connection of stud welding pistol 5 3 3 Mains supply e e Connect welding cable of welding pistol or welding head to the welding cable socket item 11 chapter 5 1 and lock by turning to the right until stop Insert control cable into control cable socket item 10 chapter 5 1 and secure by locking the spring bands Please observe the connecting instructions given in the operating instruc tions for the welding pistols Connect mains cable to power supply IN MORTAL DANGER Only connect stud welder to authorized earthed sockets 5 4 Adjustment of lift 5 24 RT
35. ix A PS 3 Adjustment of stud welding pistols Capacitor Discharge 1 3 Adjustment of spring pressure does not apply to stud welding pistol PS 3 When using the stud welding pistol PS 3 adjust the lift instead of the spring pressure In this case please leave out chapter 1 3 and referto chapter 1 4 of Appendix A Adjustment of stud welding pistols Capacitor Discharge The pressure with which the stud is pressed against the workpiece during the welding process is called spring pressure The following illustration shows how to adjust the spring pressure of stud welding pistol PS 1 which is equipped with a spring pressure indicator Stud welding pistol PS 3K is provided with a similar spring pressure indicator For stud welding pistols PS OK and PS 1K there is no spring pressure indicator 1 Z 0041 E 1 Adjusting screw 2 Spring pressure indicator For all stud welding pistols described here the spring pressure is adjusted by means of the adjusting screw 1 The adjusted pressure is indicated at the spring pressure scale 2 Adjust spring pressure as follows e Turn adjusting screw 1 to the left until stop Indicator position 1 low pressure e Turn adjusting screw 1 3 5 turns to the right Indicator position 2 medium pressure Turn adjusting screw 1 to the right until stop Indicator position 3 high pressure The spring pressure to be adjusted depends on the material of both welding stud and workpiece
36. le are standard values which are exclusively valid for studs supplied by SOYER They may vary depending on the type of workpiece the workpiece thickness the surface condition and on environmental conditions e g low outdoor temperatures The settings of the welding pistol or welding head also influence the welding parameters if e g the lift is increased normally the charging voltage has to be increased too Random samples should be taken during any production process to ensure constantly good welding results see DVS Guideline Part 1 Quality assurance of stud welding joints The welding parameters were determined with the stud welder BMS 10N and the stud welding pistol PS 3 using a lift adjustment of about 2 5 mm A steel plate with a thickness of 2 mm served as base metal for welding copper plated capacitor studs made of ST 37 3 as per DIN 32501 The values for the charging voltage are possibly somewhat lower when using the amplified stud welder BMS 10NV 220 200 180 160 140 120 100 80 60 Charging voltage V M3 M4 M5 M6 M8 Stud diameter Z 0048 E Initiation soyer 5 6 Material combinations 5 26 Stud material Base material St36 2 Ws 1 4303 CuZn37 AlMg 3 AlSi12 AI 99 5 stainless or Ms63 similar Steel up to C 0 30 1 2 1 0 0 0 Steel up to C 0 60 0 2 0 0 0 0 Steel plate leaded 2 2
37. lementary informa tion Chapter 2 Description of stud welder Description of tip ignition technology and of the stud welder e Chapter 3 Safety instructions All safety regulations which are relevant with regard to installation and operation of the stud welding system Chapter 4 Installation of stud welder e Chapter 5 Initiation Chapter 6 Operation e Chapter 7 Quality control Chapter 8 Maintenance Maintenance measures Chapter 9 Troubleshooting Errors possible causes and remedies Chapter 10 Transport and storage e Chapter 11 List of standards and guidelines e Chapter 12 Terms of warranty e Chapter 13 Spare parts 1 3 General soyer 1 5 2 Information on operating instructions Legal relationship We draw your attention to the fact that the contents of these operating instruc tions are neither part of any former or existing arrangement pledge or legal relationship nor are designed for modifying the latter All obligations of Heinz Soyer Bolzenschwei technik GmbH result from the respective contract of purchase which also comprises the complete and generally valid warranties These contractual warranty terms are neither extended nor restricted by the implementation of these operating instructions WARNING Do not carry out any actions on the stud welder without specifically knowing the operating instructions or the respective part Ensure that only qualified personnel famili
38. llows e Loosen counternut 3 e Insert stud 1 into stud holder The top edge of the stud flange must project for about 1 5 mm from the front edge of the stud holder RT The stud must make contact with the stop screw 4 Adjust stop screw 4 in the stud holder by turning it until the distance from the top edge of the stud flange to the front edge of the stud holder equals 1 5 mm Lock stop screw 4 by means of counternut 3 A 1 soyer Appendix A PS 3 Adjustment of stud welding pistols Capacitor Discharge 1 2 Installation of stud holder into stud welding pistol The illustration below shows how to install the stud holder into the stud welding pistols PS 1 PS 3 and PS 3K Stud welding pistols PS OK and PS 1K are provided with a support tube instead of pistol legs 1 SZ05 0693 010 X 1 Pistol leg 4 Bellows 2 Stud holder 5 Spring piston 3 Sleeve nut 6 Stud flange Loosen sleeve nut 3 at stud welding pistol PS 1 PS 3 and PS 3K by means of socket wrench SW 17 those at stud welding pistols PS OK and PS 1K by means of socket wrench SW 14 Insert stud holder 2 into spring piston 5 until stop e Tighten stud holder 2 with sleeve nut 3 LS The stud flange must project from the top of the pistol legs or the support tube for the thickness of the flange If this is not the case remove stud holder and correct the projection by means of stop screw A 2 Append
39. lly loaded by means of an appropriate tension device until they break If the customer demands that a certain percentage of the welded studs should be tested with a specific test load in production a tension device with load indicator should be used If the stud breaks outside the welding zone the test is regarded as successful If it breaks within the welding zone however the fractured surface must be examined The unwelded surface may not exceed a maximum of 20 of the welding surface When in doubt the breaking load in accordance with DIN 267 part 3 should be determined Quality control soyer 7 5 4 Bend test 7 30 Ifthe quantity of defective studs in one random test exceeds the acceptance number specified in DIN 267 part 5 as per AQL 4 it is necessary to find out the reason for the faults The setting values must be modified and the test repeated The bend test is a simple work test which serves to roughly check the setting values selected The welding zone is subjected to undefined tension pressure and bending A minimum of 3 studs is welded and bent to an angle of 30 by means of a tube that is slipped over the stud The test is considered as suc cessful if no superficial fissure or fracture is detected in the welding zone The acceptance number in accordance with DIN 267 part 5 as per AQL 4 must be complied with If the quantity of defective parts in one inspection lot exceeds the acceptance number AQL 4 see DIN
40. nd not to the complete stud welder 3 16 Installation of the stud welder 4 Installation of the stud welder The sides of the stud welders BMS 10N and BMS 10NV are equipped with two plastic handles RS These carrying handles are intended for transport by hand only Never pull ropes through these handles to lift the system by crane to the installation site The system would become unstable and might tilt from its original position As a result the handles could rip and the system fall on the ground e e Only place the stud welder on an even surface Four anti vibration pads located on the bottom of the system guarantee its anti skid position and serve as vibration dampers Although the stud welder is resistant to environmental influences it should be protected against dampness and dust This is easily achieved by placing the welding system on a workbench Please pay particular attention to the bearing strength of the workshop furniture and a safe and stable position Make sure there is sufficient free space around the air apertures Install the stud welder close to the welding location Observe the correct connected loads for electrical connections The electrical connecting cable is of adequate length Additional extension cables cause a voltage drop possibly leading to unit disturbances Ensure sufficient ventilation of the working room when operating the system LS The housing of the stud
41. ngen en eg idw Haare Zn cer Unies anderer Richtlinien der Europ kshen Union als der EMW Richllinie dienen Diese Best tigung bezieht sich auf das gepr fte Muster 24 09 1995 Zertifikat Certificate Zertifikat Nr Cernifleate No Blatt Page T V Rheinland Sicherheit una Uneweltachuts GmbH Am Graven Stein D 51105 K ln 2510356 ol Ihr Zeichen Client Reference Unser Zeichen Our Reference Ausstollungsdatum Daze of Issue Herr Helbig 00941 Sche E9510427801 97 03 95 Genchmigungsinhaker License Holder Fertigungssi tte 9 Manufacturing Fiam Heing Soyer Heing Soyer Eslzenschweil technik GmbH Bolrenschwei technik GmbH Inninger Stra e 14 Inninger Strafe 14 D 92237 H rthses Etterschlag D 82237 W rthsee Etterschlag Pr fzeichen Test Mark Gepr ft mach Tested acc to BIN VDE OS4dd Teil 1 10 91 EM o0974 1 05 90 enill 53 Atech 1 G5G act lo 53 Art 1 G5G Zertifieierbes Produkt Gerdteidentifikation Lineneentgelte Einheit Certified Product Product dobenejficaion License Fee Unit LICHTBOGENSCHWEIEGER T Bolzenschwei er Bezeichnung Serie BMS a BMS 4D dAD 6I 5H 8H 10N Nennspannung AC 230 V 50 50 Hz Sehutzart IP 21 Fi ANLAGE 1 Zerlifizierungs und Pr fstelle f r Ger tesicherheit Froduktzerilfigderung Der Siellrerircier d Zeriifizlerwngs wad Pra stelle zugrunde The Tess Merk Regulation i an integral pant of thir certificate Dipl Ing F Althoff soyer
42. of the head from the welded stud Operational sequence Ready SOW Start i Reloading Reloading is triggered when the head is removed from the stud It is recommended to set a waiting period of about 500 ms after the stud has been positioned on the workpiece SOW and after the welding has been completed This ensures a stabilization of the welding head is achieved prior to the welding and that the welded area can settle down after the welding Z 0068 E 2 9 soyer Description of stud welder 2 7 Alteration of supply voltage Mains supply Mains supply Line Line Binding post black violet black violet orange grey orange grey or white or white Supply 230V Supply 115V SZ 0069 E Safety instructions Safety instructions These operating instructions contain basic instructions which have to be complied with during installation and or operation It is therefore absolutely necessary that these operating instructions are read by the operator and responsible specialist staff prior to assembly and initiation They must always be available at the installation site Not only the general safety instructions listed under this main item but also the special safety instructions e g for high temperatures voltages etc listed under the other main items have to be complied with 3 1 Description of reference signs in the operating instructions The non observance of safety instructions can cause d
43. on 8 2 Replacement of components Defective components may only be replaced by trained SOYER servicemen Perfect function of your stud welder can only be guaranteed if original SOYER Spare parts are used A MORTAL DANGER Ensure that the mains plug has been disconnected and the capacitors are discharged before opening the housing to replace components 8 31 Troubleshooting soyer 9 Troubleshooting 9 32 The following list of errors their causes and remedies is designed to help you eliminate any trouble immediately on the spot If it is difficult or impossible to eliminate the trouble please contact the SOYER customer service responsible for your area or Heinz Soyer Bolzenschwei technik GmbH For address and telecommunication data please refer to chapter 1 6 page 1 4 IN MORTAL DANGER Always disconnect the connecting plug from the socket before opening the housing ofthe stud welder Only trained and appropriately qualified person nel are allowed to open the housing and to carry out works on the electric power supply and stud welder A DANGER OF ACCIDENTS Only trained and appropriately qualified personnel are allowed to replace components of the stud welding system A MORTAL DANGER Before replacing any components make sure that the capacitors are dis charged Troubleshooting Error Cause Elimination System does not weld no or only poo
44. ons before starting the system Only qualified personnel are allowed to operate the system Prevent unauthorized use of the system by children or unqualified personnel Wear non combustible closed working clothes Wear a leather apron to protect your clothes from welding spatters that are generated during the welding process Wear a head protection when carrying out welding works above your head A MORTAL DANGER When welding do not wear clothes soiled with easily combustible substances such as oil grease and paraffin oil etc Wear gauntlet gloves made of leather Wear neither rings watches nor electrically conductive jewellery Wear protective goggles with eye protecting lens of shade number 2 DIN 58211 Part 6 to protect your eyes from welding spatters and flashes of light that are generated during the process Wear side shielded glasses when knocking off ceramic ferrules Wear ear protection Capacitor discharge generates a loud bang Safety instructions soyer 3 7 Before starting welding Check the state of all cables before starting to weld Immediately replace defective cables and cable connections Ensure that the air apertures of the housing are not covered Heat accumu lation may damage the stud welder 3 8 Safety precautions at installation site e When placing the stud welder on tables or similar workshop furniture ensure that the stud welding system stands firmly and that the
45. perating personnel for stud welding see DVS Guideline 0905 part 2 section 4 Proof of qualification In the case of components which documentation must be provided for or stud welding works which as per DIN 4100 DIN 4113 are subject to acceptance the processing company must submit a certificate of competence or a proof of qualification for working with stud welding equipment see DVS Guideline 0905 part 2 sections 4 1 and 4 2 The proof of qualification applies in particular to the fastening of structures that are relevant in terms of safety regulations When being used in the building industry only approved base and stud materials may be used for example see DIN 4100 section 2 1 certificate of approval for stainless steel ifBT DIN 4113 part 2 7 4 Type and scope of test Provided that the SOYER stud welding system is properly used and the materials are appropriately selected the strength of the welding joint welding zone will always be stronger than that of the stud or base material The follow ing tests are carried out in general practice e Standard work test see DVS Guideline 0905 part 2 section 5 1 2 e Simplified work test see DVS Guideline 0905 part 2 section 5 1 2 7 4 1 Standard work test 7 28 Generally standard work tests have to be carried out and supervised by the user before welding at a structure and after a certain number of welds has been made The number of welds after which a standard work t
46. r sparking System is not switched on Switch on system digital display lights up Welding or control cable are not connected properly or damaged Connect cables properly and or check for damages Replace if necessary Both earth cables are not or not properly connected and or earth clamps are not attached to the workpiece Connect earth cables attach earth clamps to the workpiece Welding points and or earth connection points at the workpiece are not metallically blank Prepare workpiece and or studs There is no arc even though system is ready for operation Stud without ignition tip or centre mark to deep for the ignition tip Use stud with ignition tip or reduce centre mark Control of stud welder or welding pistol is defective Contact SOYER customer service Stud is too loose in stud holder Press stud holder together or tighten it Stud thread is scorched Stud holder is worn Replace stud holder Varying welding results Welding energy not correctly set Set welding energy Cable connections are too loose Transition resistances are generated Check all cable connections and earth clamps for tight fit Stud too loose or not fully inserted into stud holder until stop Insert stud into stud holder until stop If necessary replace stud holder Magnetic blowing action Arc is forced into a certain direction Alter earth clamp fixture place iron parts on t
47. rs ZZ soyer Heinz Soyer jolzenschwei technik GmbH Inninger Stra e 14 82237 Worthsee Etterschlag em ented a quality system in the following areas of y application ment Production and Sales of Stud Welding Equipment N Production of Welding Studs jay of a quality audit it was proved that this quality stem has been put into service and fulfils the requirements of the Standard DIN EN ISO 9001 2000 No DE 1996 001 2 First Certification 02 12 1996 09 19 2005 D sseldorf 09 19 2002 Certification Body WU AUA Dipl Ing M Lehmann LGAN Lancksgewerbearsialt Bayern EG KONFORMITATSBESTATIGUNG ber die elektromagnetische Vertraglichket im Rahmen der unten aufgef hrten Normen Zer ikai hr EMA 2SA2202 Pr fstelle EMY Pritzentrm der LA Tityetr 2 D 90431 Nimberg Inhaber cher Heinz Soyer Botrenschweiliechnk GmbH Best tgung nae Or 14 Wiirtheee Etterschiag Hersteller din Profbericht vom 24 09 1995 5 Aulir Me 426 1270 426 1271 1428 1274 Objekibeneichnune Eolzenschwel er Universalritier Typ BMS 8H BMS 10NV UVR 2505 Pr fbseschrelhung EMy Pr fungen Pr fstendends PEH 50 199 BM 60 555 2 EN 60 555 3 Diese Kanformit isbest ligung wurde gem Artikel 10 Abs 1 der Richifinie des Rates vom 03 Malia zur Angleichung der Rechtsworschrifien der Mitgliedsstaaten Ober die aiamaa GEGEND vom ar ae Bestatigung macht keine Aussagen bezug auf die Schutzanfordenu
48. rth cables Ba y Pistol Marks control and welding cable sockets to be connected with pistol SZ 0043 E Initiation 5 3 Preparation for initiation IN MORTAL DANGER Please observe the safety instructions in chapter 3 Do not yet connect the stud welder to the mains supply Connect the stud welding pistol and earth cables to the stud welder prior to initiation 5 3 1 Earth connection Attach earth cable to earth cable connector item 12 section 5 1 and lock by turning to the right until stop Attach earth clamps to workpiece LS Ensure optimum contact with workpiece Due to the high welding current an unbalanced current distribution may cause a magnetic blow effect on the arc i e the arc for welding the stud is asymmetrical This is shown by an irregular course of the weld upset on the side of the stud The welding results are unsatisfactory and not reproducible For this reason you should attach the earth clamps to the workpiece in such a manner that the welding pistol is positioned as close as possible to the centre of the connecting route of both earth clamps This guarantees a current distribution around the stud that is balanced to the largest possible extent and satisfactory welding results Difficult areas are welds on the edge of the workpiece or greater non homogeneities in material thickness i e the sheet thickness varies by a few millimeters or additional material
49. sing Threaded rod M4x85mm Order No M01242 M01074 M01012 M01047 F03601 M01351 M01262 M01261 E02089 E01986 F01296 M01012 M01178 M01075 M01063 M01707 E03537 M01012 M01074 F03707 FA E F03617 FA E E01898 E03608 E01895 F03630 FA M01012 F03636 FA E M01031 M01012 M 1074 F03750 E02222 M01012 M01242 M01246 M01310 M01012 F03596 M01244 Spare parts 13 4 Exploded view of BMS 10N stud welder View A ri ri 10 INN S O N m 6 _ N SZ 0167 X 13 41 Spare parts soyer 13 5 Spare parts list for BMS 10N stud welder View B and C 13 42 Item No Quantity OONADUBWNE PPPPHrTH PWHMHMWWWMTMHMMTPPPPOODDH H DD D AHHH HRP We fH Description Cheese head screw M4x16 Protective grating Fan 220 230 volt Covering plate for fan Hexagon nut M4 Spring ring M4 Spring ring M4 Hexagon nut M4 Flat head screw M4x16 Cheese head screw M4x12 Spring ring M6 Hexagon nut M6 Fan elbow Fan 24V TYPE 4715KL Hexagon nut M4 Spring ring M4 Spring ring M5 Hexagon head cap screw M5x12 Hexagon nut M4 Spring ring M4 Nylon washer Insulating disk Busbar left Busbar middle Busbar right Hexagon nut M8 Spring ring M8 Washer M8 Connecting cable Connecting cable Hexagon head cap screw M8x16 Aluminium capacitor 22000uF Connecting cable Connecting cable Insulating plastic tube 175mm Threaded ro
50. thorized and qualified technical personnel Generally only work at the system when it has been switched off and after having it disconnected from the mains supply It is indispensable to comply with the procedure for stopping the stud welding system described in the operating instructions chapter 3 13 Immediately after having completed your work re install and activate all safety and protective devices 3 11 Unauthorized retrofit and spare parts production The system may only be retrofitted and modified after consultation with the manufacturer Original spare parts and accessories authorized by the manufac turer guarantee safety The use of other parts may result in the cancellation of warranty for any consequences thus caused 3 12 Inadmissible operating methods Limit values Working safety of the stud welding system supplied can only be guaranteed if the stud welder is used in accordance with its purpose The limit values indi cated in the chapter Technical data must never be exceeded 3 13 Stopping the stud welding system 3 13 1 Stopping the stud welder when welding with normal operation Switch off the mains switch item 2 chapter 5 1 of the stud welder e Disconnect the mains plug from the socket Disconnect the earth cables item 12 chapter 5 1 the control cable item 10 chapter 5 1 the welding cable item 11 chapter 5 1 from the stud welder e Rollup the cables without buckling them soyer
51. ud welder 2 22222 3 14 3 10 Safety instructions for maintenance inspection and assembly works 22222222S O oO 3 15 3 11 Unauthorized retrofit and spare parts production eee 3 15 3 12 Inadmissible operating methods 2 22222 3 15 3 13 Stopping the stud welder 2 2222 3 15 3 13 1 Stopping the stud welder when welding with normal operation _____ eee 3 15 3 13 2 Stopping the stud welder when welding with automatic operation ee 3 16 3 14 The S symbol 2 222 3 16 4 Installation of stud welder _ Z 2 2 2 222 4 17 5 Initiation __ 2 2 2 2 0 0 20 2 ee i te ee in AT et 5 18 5 1 Front and rear view 000000000 5 18 5 2 General description 000000000 LI 5 19 5 2 1 Operating elements 2 2 0000 LI 5 20 5 2 2 Display elements 20 20 0000 0 Lo LI 5 20 5 2 3 Connecting elements 00 0000 LI 5 20 5 2 4 BUSOA Sn oP Be Sa EN at Aa are Ma ta tale Sh Keen real et 5 21 5 2 5 SVIMDOIS ees re De nn a ne ee Bin Pets bo aati SONA nn SEN Dea re ASE 5 22 5 3 Preparation for initiation_ 2 0 0000 5 23 5 3 1 Earth Connection 00000000 5 23 5 3 2 Connection of stud welding pistol ee 5 24 5 3 3 Mains supply 5 24 soyer Contents 5 4 Adjustment of lift _____ 0 000000000000 0 oo LI 5 24 5 5 Welding parameters 000000000 LI 5 25 5 6 Material combination 2 222 5 26 6 Operations 2 nnna aa a ee he ee ae aada 6 27 7 Quality control __ _ LLLLLIN 7 28 7 1 ATEEN 3 ee AET E NE en 7 28 7 2 Demands on the company ee 7 28 7 3 Proof of qualification 22222 7 28 7 4 Type and scope of test
52. welders BMS 10N and BMS 10NV corresponds to safety class IP 21 Please observe that this system of protection is e g not suitable for being operated or transported in the rain soyer Initiation 5 Initiation 5 1 Front and rear view Both stud welders BMS 10N and BMS 10NV have identical front and rear views soyer BMS 10N Lee Te 13 12 11 10 98 Front view 1 Fuse element with fuse 0 1 AT 8 Air function forward optional 2 Main switch 9 Air function backward optional 3 Fuse element with fuse 10 AT 10 Control cable socket 4 Energy range controller 11 Welding cable socket 5 Charging voltage display 12 Earth cable connectors 6 Function key Lift adjustment 13 Mains cable 7 LED displays Z 0044 E 5 18 Initiation 14 15 16 17 18 19 dep ds MNMTMTTNTNT VY DI 20 Rear view 14 9 pole connecting socket for 17 Type plate controlling the stud welder 18 Test label via a CNC interface 19 Compressed air supply connection 15 15 pole connection socket for feeder control optional for controlling the feeder 20 Connection sockets for compressed 16 Welding counter air control of the feeder optional Z 0046 E 5 2 General description The SOYER stud welders BMS 10N and BMS
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