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Operating Instructions Stud Welding System HesoMatic-9 GB: English ersion Read these operating instructions before starting any work! Doc.ID: P00255 : 01.2021 www.soyer.com Date of issue...
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HesoMatic-9 Stud welding gun PS-3A Operating Instructions Document no: P00155, 01-2021, translation of the original German manual (English: P00255) All information in this document is the property of Heinz Soyer Bolzenschweißtechnik GmbH Revision status Document created / modified Editor Date...
2.6.1 Prerequisites for personnel ....................16 Transport ..........................17 Storage, shutdown ......................17 Disposal ..........................17 Description of the HesoMatic-9 stud welding system ............. 18 Type differentiation ....................... 19 Working method ........................19 6.2.1 Capacitor discharge stud welding ..................20 Overview of the controls .......................
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Setup and connection of the automatic system .............. 57 10.1 Requirements for the installation location ................57 10.2 Connections of the HesoMatic-9 stud welding system ............58 10.3 Information about connecting the earth cable ..............61 10.4 Connecting the stud feed hose .................... 62 10.5...
The devices are designed and constructed in accordance with the generally accepted codes of practice. Please note that significant changes to the device will cause the declaration of conformity to become void. Furthermore, the manufacturer's warranty may be rendered invalid. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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DIN EN ISO 4414 Fluid power - General rules and safety requirements for pneumatic systems and their components Responsible person for the technical documentation: Mr. Klein, Soyer Company Place/date: Wörthsee, 24 August 2018 Undersigned person: Heinz Soyer, Managing Director Signature: ________________ Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
DIN EN 60974-9 Arc welding equipment - Installation and use Technical Bulletin DVS 0904 Instruction for practice - Arc stud welding Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Do not touch or open, danger to unauthorised persons. Danger to persons with medical implants such as pacemakers. The information sign is not a warning sign. It indicates important and useful information on the subject. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Starting the device with faulty protection devices is not permitted. Faulty protective devices must be repaired or replaced immediately. Unintentional operation by third parties must be prevented. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Danger of explosion from an inappropriate installation location in explosive atmospheres The device is not designed for use in explosive zones. The device must not be installed and operated in explosive atmospheres. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Fire hazards from hot welding spatter Welding spatter or hot workpieces occurring during the welding process can result in fire hazards. Do not store combustible or highly inflammable materials in the welding area. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Check the holding device and balancer for visible signs of damage before starting work. Faulty parts have to be replaced immediately. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
® With the SOYER HesoMatic-9 capacitor discharge stud welding system, pins and threaded studs from M3 to M8 as well as many different weld fasteners made of steel, stainless steel, aluminium and brass can be welded in accordance with DIN EN ISO 13918 (capacitor discharge).
In general: Work on live elements may only be performed by authorised electricians. This work must be performed in line with the applicable technical rules for electrotechnical devices. All devices of Soyer Bolzenschweißtechnik GmbH must only be opened by ® ®...
Local environmental directives must be observed when disposing of the device. Water-endangering as well as environmentally hazardous substances are to be disposed of in accordance with legal regulations. If applicable, materials must be separated according to regulations. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
6 Description of the HesoMatic-9 stud welding system Item Designation PS-3A stud welding gun Balancer (tensile force 2 - 3 kg, adjustable) Holding device for welding gun (load capacity max. 10 kg) Energy source with feeding unit (feeder) Transport cart with storage space and drawer (lockable door) Danger due to overloading the holding device The holding device may only be used for the PS-3A stud welding gun.
■ Trouble-free transport thanks to stud feed via steps and low-noise operation ■ Monitoring of all functions using a clear function display panel ■ Automatic feeding. In connection with the PS-3A stud welding gun, the studs can be fed automatically using compressed air. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
The piece the metal sheet. material solidifies and the stud is permanently welded. For more information on this subject, please visit: www.soyer.com. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
LED operating mode (see “6.4.2 Operating states (feeding unit)” on page Rotary knob for adjusting the feed speed in the feeder bowl Min.: Minimum feed speed Max.: Maximum feed speed Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Only replace fuses when mains plug is disconnected! Should it become necessary to replace fuses, only use fuses with the specified electrical values. Oversized fuses could either cause defects on the electrical system or a fire. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
6.3.2 Rear panel/Connections Figure 2: Overview of the device back panel Item Designation Blow air regulator Type plate CNC interface Main air connection Mains connection / Mains cable Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
LED lights up when vibration drive is in operation. Automatic LED lights up with automatic operation being switched on. No function LEDs unassigned with HesoMatic-9. Malfunction LED lights up in case of malfunction. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
The reload time can be regulated based on the stud diameter. Turning to the left increases the time; turning to the right shortens the time. P 2: Frequency adjustment for the feeder vibration drive. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Technical data for HesoMatic-9 stud welding system Designation HesoMatic-9 Welding procedure Capacitor discharge stud welding Standard gun PS-3A M3 - M8 or Ø 3 - 8 mm with steel, stainless steel, aluminium and Welding area brass (M8 or Ø 8 in aluminium and brass limited, depending on the...
500 ms after a stud is positioned on the workpiece (SOW) as well as after welding. This ensures that the welded area can settle down before and after welding. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Hazards for the operator may occur when a wrong welding gun is used. Only use welding guns hereinafter permitted by Soyer GmbH. The use of other guns or guns from another manufacturer will invalidate the declarations of conformity and warranties of Soyer GmbH.
Improper cleaning may cause damage to the device. Make sure that no detergents get into the device. Do not use aggressive detergents for cleaning the device. The frequency of cleaning depends on the operating conditions of the devices. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
The feeder intensity can be adjusted via a potentiometer. This is controlled via a control panel with membrane keypad. LED display and signal transmitters on the stud escapement enable a regulated function in both continuous or automatic mode. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Each time, before you start the system, check that the stud feed hose is correctly inserted on both sides, into the feeding unit (feeder) and the gun. Only use stud feed hoses from Soyer GmbH. Never bridge the safety pressure switch at the cover hood (do not trigger the switch if the protective hood has been removed).
Safety switch to disconnect the compressed air when the protective hood is not attached. The safety switch must not be bridged! Fuse element 2 x 1 A (time-lag fuse 5 x 20 mm) - feeding unit Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Feeder bowl with welding studs Connection piece for the stud feed hose (replaceable part) Outlet rail (replaceable part) Blow-off nozzle to separate studs from on top of one another Hold-down plate Stud retainer Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Threaded studs M10, aid to remove the stud retainer Outlet rails with distance piece All conversion set parts can be ordered separately. For this, please observe chapter “16.1 Feeder conversion set” on page 83. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Turn off both device switches (a). Disconnect the main air feed (b) at the back panel of the device. Remove the cover hood (d) via the fastening screws (c) on both sides. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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(a). Studs which are parallel to one another or on top of one another (b) then fall off the plate. After the adjustment, tighten the clamp screws (b) again. The step width is adjusted. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Allen key if required. Step 3: Remove the required hose connection from the conversion set. Each hose connection is labelled with the stud diameter it must be used for (a). Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Ensure that the hose end is clean, straight and free of burrs. Lightly chamfer the internal diameter of the hose, to avoid studs becoming stuck (e.g. with the 60° countersink F04922 from Soyer). Insert the hose into the connection piece until the stop.
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To remove and insert the stud retainer, use a screw or a stud with diameter M 10 which you screw into the centre (c). Remove the screw/stud again after inserting the barrel. Step 4: Loosen the fastening screws (a). Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Insert the outlet rail (a) and the panel with the compressed air connection (b). Fasten both with the tommy screw (c) and the fastening screw (d). Ensure that the compressed air line and the compressed air nozzle are not damaged by this. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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If not, open the tommy screw (b) and push the block on the transition (c) until there is a clean, aligning transition. Step 9: Attach the hold-down plate with the fastening screw (a) above the outlet rail. The outlet rail has been changed. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Each limit stop distance plate is labelled with the stud diameter it must be used for (a). Step 4: Attach the limit stop distance plate (a) and clamp it with the tommy screw (b). The limit stop distance plate has been changed. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
For example, the pressure required depends on the stud diameter and weight, as well as on the length of the stud feed hose. Here, observe the maximum permitted pressure (see chapter “6.6 Technical data for HesoMatic-9 stud welding system” on page 26). Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Blow-off nozzles Part being blown off (example) Valve for regulating the blow-off air The blow-off nozzles prevent an incorrectly positioned stud from being transported further. The blow-off air is adjusted via a central valve. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
The transport speed to be adjusted depends on the type and size of the welding studs. The welding studs must be transported upwards evenly, without gaps and without being pushed on top of one another. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
To adjust this, the compressed air remains switched off and the device main switch is connected to power. Push the feed slide into the end position of the limit switch being adjusted. Then, move the limit switch until its LED lights up. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Outlet rail or stud escapement is set for too great a diameter. Use the correct distance piece according to the stud diameter. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Problems with the stud feed hose. Check the internal diameter. Check for damage or kinks (and radii which are too small). Check the hose ends, chamfer the inside of the hose end if necessary. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
The height of the lift is also decisive for the welding result. The height of lift can be determined via the lift time using the HesoMatic-9 stud welding system. See chapter “11.3.3 Adjusting the lift time (height of lift) in the setting mode” on page 72.
Manually rotate the union nut (a) onto the stud feed pipe (b) until the stop. The assembly is complete. Insert the stud feed pipe into the gun as described in chapter “9.2 Inserting the stud chuck and stud feed pipe” on page 55. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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For this reason: To avoid damage to the clamp of the stud feed pipe in the gun, it is recommended to always remove the stud feed pipe from the gun when changing the hose. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Welding spatters and slag can have sharp edges. Wear protective gloves when cleaning. ® We recommend the use of SOYER separating spray to prevent impurities from welding spatters and slag and to simplify the cleaning process (order number: M01464). Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Corresponding to the stud diameter, stud chucks must be installed/changed in the gun. The following describes the adjustable stud chuck for the automatic gun PS-3A. Figure 13: Stud chuck for PS-3A stud welding gun Item Designation Stud Plunger Stud chuck Distance sleeve Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
1.5 mm and 3 mm above the stud chuck with its flange upper edge. Step 4: Place a distance sleeve or filling dis- tance part combination between the plunger and the stud chuck. The adjustment is complete. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Use the plunger to push the stud chuck into the air cylinder (a) until the stop. attention installation position (guide pin) of the stud chuck! Then, fix the stud chuck in place with the union nut (b). Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Adjust the position of the support in such a way that the stud protrudes 1.5 - 3 mm above the support. Fix the support into place after adjusting with the four Allen screws. The assembly is complete. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Danger from welding vapours Vapours that are dangerous to health may occur, depending on the material of the workpiece and/or the welding stud. Where necessary, ensure suitable extraction of the welding vapours. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
10.2 Connections of the HesoMatic-9 stud welding system The following describes how to connect the device. Connecting the front panel of the device Step 1: Device switches OFF? Check that both device switches (a) are off. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Connect both compressed air hoses for the plunger (c) from the hose package. Observe the labelling on the connection and hose, do not mix up! The front panel of the device is connected. Observe the coloured marking of the cables when connecting them. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Check that both device switches (a) are off. Step 2: Earth connection Use the mains plug (a) to connect the device to the power supply. See chapter “6.6 Technical data for HesoMatic-9 stud welding system” on page 26. Step 3: Supply air Connect the main line to the compressed air supply (a).
Ideal condition, stud is located in the centre of the two earth connections. Asymmetrical earth connection The arc is deflected to the side where there is a lower current density. Workpiece geometry Additional workpiece masses disturb the arc symmetry. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
If the stud feed hose is used incorrectly, or an unsuitable hose is used, there is a risk of injury due to ejected welding studs. Only use original stud feed hoses from Soyer GmbH. Only ever use stud feed hoses which match the stud diameter.
Manually rotate the union nut (a) onto the stud feed pipe (b) until the stop. The assembly is complete. Insert the stud feed pipe into the gun as described in chapter “9.2 Inserting the stud chuck and stud feed pipe” on page 55. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
The feeder is supplied with the corresponding conversion parts. You can find the conversion parts required for the gun in chapter “16.2 Spare and wear parts for the gun and stud chuck” on page 85. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
(automatic reloading) "ON" with automatic stud feed "OFF" with manual stud feed Trigger delay: Do not change. Leave on the factory setting. The trigger delay is only used for CNC or robot operation. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Step 3: After approx. 3 seconds, the button Ø 3 is activated and the feeder operating mode is displayed on the screen. To adjust the parameters, see the following table. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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0.0 to 1.0 s, in 0.1 s stages pre-load time [Factory setting: 0.5] Ø 7.1 Feeder reload 0 to 20 s, in 1 s stages time [Factory setting: 1] Ø 8 End the adjustment menu. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Step 3: After approx. 3 seconds, the button Ø 3 is activated and the number of repair attempts is displayed on the screen. To adjust the parameters, see the following table. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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[Factory setting: 25] Ø 6 Automatic reload 0: OFF 1: ON [Factory setting: 1] Ø 7.1 Trigger delay 0.0 to 1.0 s, in 0.1 s stages [Factory setting: 0] Ø 8 End the adjustment menu. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Lift time In the tables, you will also find experience values for adjusting the lift time (see chapter “11.3.3 Adjusting the lift time (height of lift) in the setting mode” on page 72). Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Welding parameter adjustment aid for HesoMatic-9 stud welding system Device button Ø Ø3 Ø4 Ø5 Ø6 Ø7.1 Ø8 [mm] Corresponds to threaded stud Charging voltage preset [V] Guideline value for With PS-3 und PS-3A welding guns: 9 - 10 ms...
If the control plug of the gun is disconnected during the lifting test, the device displays “Con” for approx. 3 seconds and starts operating mode automatically. If no gun type is displayed on the screen after switching to adjustment mode, you are in operating mode. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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A gap welding gun with lifting magnets not recognised as a PS-9 is automatically displayed as a PS-3 gun. If all three criteria are not fulfilled, you are in operating mode and the welding is carried out when you then push the release button. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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If the lifting cycle takes place without the notification that the studs are on the workpiece, instead of the lift time, [- - -] is displayed, as no earth connection was present. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Check or convert the automatic system according to chapter “11 Step 3: Converting/adjusting the automatic system” on page 64. Step 4: Fill the feeder bowl (a) with welding studs. ® Only use SOYER welding studs. Observe the permitted filling weight. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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Ensure that the welding points on the stud and workpiece are metallically bright. Step 9: Press the gun onto the workpiece at an angle of 90 degrees. When using a contact gun, press it firmly against the spring force. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Observe the permitted filling weight and that the stud type is the same. Afterwards, assemble the protective hood. The compressed-air supply is re- established and the work can be continued. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
Poor welding joint, e.g. due to a blow effect or a welding gun that was shaken or applied at a slant. The stud flange is not welded completely and has visible imperfections. Undercuts are visible. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
12.4 Welding defects and their causes The most common weld defects, their possible causes and how to troubleshoot them are described in the following. If a problem cannot be solved, please contact Heinz Soyer Bolzenschweißtechnik GmbH. Faults Possible cause and troubleshooting Device does not Stud welding device is not switched on.
12.5 Malfunctions with an error message on the stud welding device Dangers during troubleshooting During troubleshooting, various dangers may occur. Soyer Bolzenschweißtechnik GmbH devices must only be opened by Soyer personnel or personnel authorised by Soyer. For troubleshooting, the device must be disconnected from the main power supply and secured against accidental switch-on.
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In the event of error code E05, excess temperature, the welding device cannot be used until the displayed error message disappears. If the devices works with a reduced charging current due to a high internal tem- perature, the LED “Malfunction” flashes. Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
13 Maintenance and repair Maintenance and repair of the stud welding system and the stud welding guns should only be performed by Heinz Soyer Bolzenschweißtechnik GmbH or authorised specialists. 14 Service If servicing is required, please contact: Heinz Soyer Bolzenschweißtechnik GmbH Inninger Straße 14...
F02570 Ø 7.1 mm F01081 Stud feed hose (always cut by metre. Please F01082 state desired length in F01083 metres). Item quantity 1 means 1 m. F01084 M8 / Ø 7.1 mm F01085 Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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M8 x 10 mm F06403* Pushing piston for short M5 x 6 mm F04865 studs M6 x 8 mm F04866 Ø 7.1 x 10 mm F04867 M8 x 10 mm * Availability on request Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik...
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