Soyer HesoMatic-9 User manual

Operating Instructions
Stud Welding System
HesoMatic-9
GB: English Version
Read these operating instructions before starting any work!
Doc.ID: P00255
Date of issue: 01.2021
www.soyer.com

Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik 3
Device numbers
We recommend entering the device numbers here so that they can be
accessed quickly if servicing is required.
Device
Type
Serial number
Stud welding system
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
Original
modified
MS/IS
January 25th, 2021

4 Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik
CONTENTS
1General information .............................................................................................................. 6
1.1 Validity of the operating instructions ...................................................................................... 6
1.2 Registered trademarks........................................................................................................... 6
1.3 Declarations of conformity...................................................................................................... 6
1.4 Manufacturer.......................................................................................................................... 8
1.5 Instruction, training................................................................................................................. 8
1.6 Standards and directives........................................................................................................ 8
2Important safety instructions............................................................................................... 9
2.1 Safety alerts used .................................................................................................................. 9
2.2 General safety instructions................................................................................................... 10
2.3 Safety instructions for the working method.......................................................................... 13
2.4 Personnel protective equipment........................................................................................... 14
2.5 Intended use of the stud welding system............................................................................. 15
2.5.1 Incorrect use.................................................................................................................... 15
2.6 Operating company prerequisites........................................................................................ 16
2.6.1 Prerequisites for personnel.............................................................................................. 16
3Transport.............................................................................................................................. 17
4Storage, shutdown.............................................................................................................. 17
5Disposal ............................................................................................................................... 17
6Description of the HesoMatic-9 stud welding system..................................................... 18
6.1 Type differentiation............................................................................................................... 19
6.2 Working method................................................................................................................... 19
6.2.1 Capacitor discharge stud welding.................................................................................... 20
6.3 Overview of the controls....................................................................................................... 21
6.3.1 Overview of the front panel.............................................................................................. 21
6.3.2 Rear panel/Connections .................................................................................................. 23
6.4 Display of the operating states............................................................................................. 24
6.4.1 Operating states (stud welding system)........................................................................... 24
6.4.2 Operating states (feeding unit) ........................................................................................ 24
6.5 Special functions (feeder control)......................................................................................... 25
6.6 Technical data for HesoMatic-9 stud welding system.......................................................... 26
6.7 Interface HesoMatic-9.......................................................................................................... 27
6.8 Permitted welding guns........................................................................................................ 28
6.9 Cleaning the stud welding system........................................................................................ 29
7Description of the feeding unit (feeder)............................................................................ 30
7.1 Safety information with automatic operation........................................................................ 31
7.2 Overview of feeding unit....................................................................................................... 32
7.3 Converting the feeding unit .................................................................................................. 34
7.3.1 Carrying out the conversion............................................................................................. 35
7.4 Adjusting the feeding unit..................................................................................................... 43
7.4.1 Adjusting the blow air regulator ....................................................................................... 43
7.4.2 Adjusting the blow-off nozzles......................................................................................... 44
7.4.3 Adjusting the transport speed of the weld studs.............................................................. 45
7.4.4 Readjusting the limit switch.............................................................................................. 46

Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik 5
7.5 Correcting malfunctions of the feeding unit.......................................................................... 47
8Description of the PS-3A stud welding gun ..................................................................... 49
8.1 Inserting the stud feed hose................................................................................................. 50
8.2 Technical data for the PS-3A stud welding gun................................................................... 52
8.3 Cleaning the stud welding gun............................................................................................. 52
9Description of the stud chuck for the PS-3A.................................................................... 53
9.1 Adjusting the stud chuck ...................................................................................................... 54
9.2 Inserting the stud chuck and stud feed pipe ........................................................................ 55
10 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 Connections on the welding guns........................................................................................ 63
11 Converting/adjusting the automatic system .................................................................... 64
11.1 Converting the automatic system for the stud diameter ...................................................... 64
11.1.1 Conversion sets........................................................................................................... 64
11.2 Adjusting the device parameters.......................................................................................... 65
11.2.1 Explanation of the parameters .................................................................................... 65
11.2.2 Adjusting the main parameters.................................................................................... 66
11.2.3 Adjusting the ancillary parameters.............................................................................. 68
11.3 Adjusting the charging voltage and lift time on the stud welding system............................. 70
11.3.1 Tables for adjusting the device.................................................................................... 70
11.3.2 Adjusting the charging voltage .................................................................................... 71
11.3.3 Adjusting the lift time (height of lift) in the setting mode.............................................. 72
12 Welding operation with the automatic system................................................................. 75
12.1 Starting the automatic system and carrying out welding ..................................................... 75
12.1.1 Refilling the feeder during operation ........................................................................... 77
12.2 Notes on checking the quality of the weld............................................................................ 78
12.2.1 Visual inspection.......................................................................................................... 78
12.3 Switching off the devices...................................................................................................... 79
12.4 Welding defects and their causes ........................................................................................ 79
12.5 Malfunctions with an error message on the stud welding device......................................... 80
13 Maintenance and repair...................................................................................................... 82
14 Service.................................................................................................................................. 82
15 Warranty conditions............................................................................................................ 82
16 Spare and wear parts.......................................................................................................... 83
16.1 Feeder conversion set.......................................................................................................... 83
16.2 Spare and wear parts for the gun and stud chuck............................................................... 85

6 Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik
1 General information
These operating instructions contain important information and rules for the operation
of the devices. Keep the operating instructions in a readily accessible location close to
the devices.
The term 'Devices' in the operating instructions refers to the stud welding system and
the stud welding gun.
Carefully read the operating instructions and any other documents contained in the
technical documentation. Pay particular attention to the safety instructions which are
intended to help you recognise any possible residual risks and prevent hazards.
The drawings and diagrams in these operating instructions are for illustration purposes
and may vary slightly from the actual equipment.
The manufacturer reserves the right to make technical changes.
1.1 Validity of the operating instructions
These operating instructions apply to the following devices:
Stud welding system HesoMatic-9
Stud welding gun PS-3A
1.2 Registered trademarks
The following terms in these instructions are used with registered trademarks:
SOYER®: Developments/technologies of Soyer GmbH.
1.3 Declarations of conformity
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 7
Conformity declaration –Stud welding system
EC Declaration of Conformity
in accordance with the EC Machinery Directive 2006/42/EC of 17 May 2006, Annex II A
We herewith declare that the design and construction of the machine described below as well as in the
version marketed by us meet the fundamental safety and health requirements of the EC Directive
2006/42/EC. Any modification of this machine without our confirmation shall automatically annul this
declaration.
Manufacturer:
Heinz Soyer Bolzenschweißtechnik GmbH,
Inninger Straße 14
D-82237 Wörthsee, Germany
Phone: [phone]
Description of the machine:
• Function: Stud welding system (unit consisting of feeder and stud welding device)
• Type/Model: HesoMatic-9
• Serial number: ________________
• Year of manufacture: ________________
The product is conform with other directives/regulations applicable to the product:
• EC Low Voltage Directive 2006/95/EC
• EMC Directive (2004/108/EC) of 15 December 2004
Harmonised standards applied, in particular:
DIN EN 12100-2011-03 Safety of machinery - General principles for design, risk assessment and
risk reduction
DIN EN 60204-1 Safety of machinery - Electrical equipment of machines, Part 1: General
requirements
DIN EN 60974-1 Arc welding equipment; Part 1: Welding power sources
Other technical standards and specifications applied:
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: ________________

8 Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik
1.4 Manufacturer
The manufacturer of the devices is:
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
82237 Wörthsee
Phone: [phone]
Fax: [phone]
Email: [email protected]
Web: www.soyer.de, www.soyer.com
1.5 Instruction, training
SOYER®offers optional and individual instruction in the operation of the devices.
Moreover, SOYER®offers training for customer-specific use of the devices.
Information on the scope and costs of instruction and training can be obtained
from Soyer GmbH.
1.6 Standards and directives
The following standards, inter alia, must be observed for carrying out stud welding
work and for the qualification of personnel:
DIN EN ISO 14555 Welding —Arc stud welding of metallic materials
DIN EN ISO 14732 Welding personnel - Qualification testing of welding operators and
weld setters for mechanised and automatic welding of metallic materials
DIN EN 60974-9 Arc welding equipment - Installation and use
Technical Bulletin DVS 0904 Instruction for practice - Arc stud welding

Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik 9
2 Important safety instructions
Read the following chapters carefully and follow the safety instructions. If you are
uncertain or an instruction cannot be followed, please contact the manufacturer.
The devices have been constructed according to the generally accepted codes of
practice and in compliance with, and application of, the usual and established safety
requirements. In order to reach maximum safety, it is essential that all of the safety
instructions in these operating instructions are heeded and followed.
2.1 Safety alerts used
Warning signs are used in this document, depending on the potential danger of the
situation.
Safety and information symbols used in this manual
This warning sign indicates imminent danger leading to
severe injuries or death.
This warning sign indicates a potentially dangerous
situation that may lead to severe injuries or death.
This warning sign indicates a potentially dangerous
situation that may lead to minor injuries.
Without the warning triangle, this warning sign is also
used in the event of danger of material damage.
Additional information indicating danger from electric
current. The additional sign is used in conjunction with
a warning sign.
Additional sign indicating the danger of burns. The
additional sign is used in connection with a warning
sign.
Do not touch the surface or the housing: Shock hazard.
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.

10 Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik
Safety instructions on the devices
As an additional warning of danger, warning labels can be found on the devices.
Warning labels are affixed by the manufacturer and must not be removed. If a warning
label is damaged and thus illegible, a new warning label must be affixed immediately.
Warning labels must be obtained from the manufacturer.
2.2 General safety instructions
Danger from electric current, general information
When working on live components, there is a danger to life from electric current.
Work on electric or electronic components may only be performed by trained
electrotechnical personnel in accordance with currently applicable
electrotechnical regulations.
Protection devices must not be manipulated or disabled. Protection devices
include, for example, housing and housing cover, fuses or power switches.
If protection devices have to be removed for maintenance work, the device
may only be switched on again when all protection devices are installed and
their functionality has been checked.
Starting the device with faulty protection devices is not permitted. Faulty
protective devices must be repaired or replaced immediately. Unintentional
operation by third parties must be prevented.

Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik 11
Danger from electric current during maintenance and repair
When working on live components, there is a danger to life from electric current.
Work on electric or electronic components must only be carried out by trained
electrotechnical personnel of Soyer Bolzenschweißtechnik.
Before performing any work on the stud welding device, the mains switch of
the device must be switched off and the mains plug of the stud welding
device must be disconnected.
Before performing any work on the stud welding gun, the supply cables to
the stud welding device must be disconnected.
If protection devices have to be removed for maintenance work, the device
must only be switched on again when all protection devices are installed and
their functionality has been checked.
Danger from magnetic fields
In the area surrounding the device, strong magnetic fields occur during the welding
process, which may influence medical auxiliary aids and therefore result in danger to
life.
Persons with electrical medical aids (such as pacemakers) must keep away
from the devices.
The operating personnel must ensure that persons with medical aids keep
away from the devices.
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.

12 Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik
Danger of burns due to hot surfaces
During the welding process, the workpieces and some parts of the welding gun get
so hot that touching them may cause burns.
Always use personal protective equipment.
Before working on hot parts of the device, check if they have cooled down.
Do not hold the gun in the welding area.
Danger of burns from hot welding spatter
Dangerous welding spatter can occur during the welding process.
Always use personal protective equipment.
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 13
2.3 Safety instructions for the working method
Hazards due to incorrect working method
Hazards for operators and third parties can arise due to an incorrect working method.
Ensure sufficient stability and a dry installation location for the device.
Make sure you do not knock over the device or pull it down from its position
with the gun cables.
Make sure, especially with mobile use, of your own good stability during
welding.
Do not hold the workpiece in your hands during welding. The workpiece must
be securely fixed during the welding process.
Never wrap the gun lines around parts of your body (e.g. arm) as electric
fields can occur.
If the gun is not put on properly or the gun settings are incorrect, a flash can
occur during welding. Do not look directly into the flash.
The gun carries out lifting movements during the welding process. Do not
hold the gun tight in the area of moving parts.
Danger due to overloading the holding device
The holding device may only be used for the PS-3A stud welding gun. If the holding
device is overloaded it may be damaged by the prying effect or tip over together with
the stud welding system.
Check the holding device and balancer for visible signs of damage before starting
work. Faulty parts have to be replaced immediately.

14 Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik
2.4 Personnel protective equipment
It is recommended to wear personal protective equipment when working with the stud
welding device.
Danger due to missing or incorrect personal protection kit
There is a danger of burns during stud welding, especially due to hot welding
spatters. A danger of blinding can also arise due to the occurrence of strong arcs.
Always wear suitable, closed protective clothing.
Type and extent of the protective equipment depends on the respective
occurrence and intensity of welding spatter, arcs and/or noise. This varies
depending on the basic material, stud material, stud size and required
welding performance.
Please observe the following instructions for protective equipment.
Recommended personal protection equipment
Protective goggles
During welding, welding spatters and a flash occur.
Wear appropriate safety goggles with side protection
and a filter protector, if necessary.
Protective gloves
During welding, the workpieces and parts of the welding
gun get hot and welding spatters occur. Wear
appropriate, non-combustible, heat-resistant protective
gloves.
Protective clothing
Welding spatters occur during the welding process.
Wear appropriate, non-combustible and, if necessary,
heat-resistant, protective clothing.
Safety shoes
Welding spatters occur during the welding process.
Wear appropriate, non-combustible, heat-resistant
safety footwear.
Hearing protection
Depending on the welding device and the welding
application, relatively loud welding noises may occur.
Wear appropriate hearing protection.

Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik 15
2.5 Intended use of the stud welding system
The welding system described here consists of the following individual devices:
Stud welding system HesoMatic-9
Stud welding gun PS-3A
These operating instructions and the declaration of conformity only apply if the named
devices are used together as described in these operating instructions.
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 connection with the PS-3A stud welding gun, the studs can be fed into the gun
automatically using compressed air.
In automatic mode, the stud welding system may only be operated with the accessories
described in these instructions.
The devices described here can also be operated separately in other combinations. If
these are used outside of the automatic system, the operating instructions for the
respective device must be observed.
Special studs or diameters upon request.
Operation of the stud welding system must be in accordance with the technical data.
2.5.1 Incorrect use
Any use of the devices deviating from the intended use is considered as not intended.
Not intended use, unauthorised modification, separate device operation or manip-
ulation of the devices will void the declaration of conformity and warranty claims against
the manufacturer.
Misuse of the welding gun as a tool, e.g. as a hammer for checking the weld quality, is
not permitted.

16 Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik
2.6 Operating company prerequisites
The operating company of the devices must ensure that the preconditions described in
this operating manual for a safe operation of the devices are fulfilled.
These include, for example, conditions at the installation location, regulatory
requirements for a safe workplace, training of the operating personnel and qualified
personnel in using the device, if applicable, compliance with required maintenance work
as well as monitoring the intended use of the stud welding system.
These operating instructions must be stored in the vicinity of the stud welding system.
The operating company of the devices must ensure that all protection devices are
present, active and intact before the stud welding system is used.
2.6.1 Prerequisites for personnel
Operating personnel
The persons authorised to operate the devices must be familiar with the stud welding
system and trained accordingly. They must have read and understood these operating
instructions. When working with the stud welding system, they must also be able to avert
possible residual danger to themselves and third parties or minimise them as far as
possible.
To retain the qualification, the safety training must be carried out at least once a year.
In the event of failure or if maintenance becomes necessary, consult specially trained
personnel or the manufacturer.
Operators of stud welding equipment must have technical expertise for operating and
adjusting the devices properly as well as for properly carrying out weldings.
If welding personnel has to be qualified for certification of welding, the DIN EN ISO
14555 and DIN EN ISO 14732 standards are to be observed.
Trained electrotechnical personnel
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
SOYER®personnel or personnel authorised by SOYER®.

Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik 17
3 Transport
When transporting the devices, make sure they cannot be damaged. Appropriate
packaging can protect the device against weathering effects, especially moisture.
4 Storage, shutdown
During storage or shutdown, make sure to protect the devices against dirt and humidity.
Protect the stud welding system against unauthorised access by third parties.
5 Disposal
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.

18 Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik
6 Description of the HesoMatic-9 stud welding system
Item
Designation
a
PS-3A stud welding gun
b
Balancer (tensile force 2 - 3 kg, adjustable)
c
Holding device for welding gun (load capacity max. 10 kg)
d
Energy source with feeding unit (feeder)
e
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. If the holding
device is overloaded it can be damaged by the prying effect or tip over together with
the stud welding system.
Check the holding device and balancer for visible signs of damage before starting
work. Faulty parts have to be replaced immediately.
The main elements of the stud welding system and its features are described in the
following.

Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik 19
6.1 Type differentiation
Designation
Order number
Feature
HesoMatic-9
P01079
Mains voltage
230 V, 50/60 Hz, 10A
6.2 Working method
Pins and threaded studs from M3 - M8 or Ø 3 - 8 mm and a wide range of different steel
and stainless steel fasteners can be welded in accordance with DIN EN ISO 13918
(capacitor discharge) with the SOYER®HesoMatic-9 stud welding system.
The welding of aluminium and brass fasteners is also possible.
For the first time, users can automatically feed and weld pins and threaded studs in a
combination device consisting of a stud welding device and a feeding unit (feeder). This
simplifies the operator’s job and also considerably increases the quality of the welding
joints.
Product highlights
■ Easy selection of welding parameters using the function keys
■ Inverter switching power supply for maximum welding performance
■ Automatic storage of the charging voltage
■ Short charging cycles to increase productivity
■ Precise digital display of the charging voltage
■ High performance in a compact design
■ Efficient and economical conversion to 6 different stud sizes
■ Complete housing as a protection against welding spatter, dirt and noise
■ Large feeder bowl diameter of 300 mm for long studs and large filling quantities
■ 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.

20 Operating instructions HesoMatic-9 | Heinz Soyer Bolzenschweißtechnik
6.2.1 Capacitor discharge stud welding
The SOYER®stud welding system operates according to the principle of capacitor
discharge with tip ignition according to DVS bulletin 0903 (DVS = German Welding
Society). This system uses the sudden discharge of a capacitor bank to generate arc
energy.
Function principle
The stud tip is placed into
contact with the work-
piece
The ignited arc creates a
melt zone on the stud and
the metal sheet.
The stud is immersed in
the weld pool. The
material solidifies and the
stud is permanently
welded.
For more information on this subject, please visit: www.soyer.com.