Soyer UVR-300 User manual

Operating Instructions
UVR-300 universal feeder
UVR-400 universal feeder
GB: English Version
Read these operating instructions before starting any work!
Doc.ID: P00250
Date of issue:04.2021
www.soyer.com

Device numbers
We recommend entering your device numbers here so that they can be
accessed quickly if servicing is required.
Device
Type
Serial number
Universal feeder
UVR-300
Universal feeder
UVR-400
Operating Instructions
Document no: P00250, 04-2021, translation of the original German instructions
(German: P00150)
All information contained in this document is the property of Heinz Soyer
Bolzenschweißtechnik GmbH.
Revision status
Document
created / modified
Editor
Date
Original
modified
MS/IS
April 01, 2021

Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik 3
CONTENTS
1General information .............................................................................................................. 5
1.1 Validity of the operating instructions ...................................................................................... 5
1.2 Registered trademarks........................................................................................................... 5
1.3 Declarations of conformity...................................................................................................... 5
1.4 Manufacturer.......................................................................................................................... 7
1.5 Instruction, training................................................................................................................. 7
1.6 Standards and directives........................................................................................................ 7
2Important safety instructions............................................................................................... 8
2.1 Safety alerts used .................................................................................................................. 8
2.2 General safety instructions..................................................................................................... 9
2.3 Safety information for universal feeder UVR-300 / UVR-400 .............................................. 12
2.4 Personal protective equipment............................................................................................. 13
2.5 Intended use of the stud welding systems........................................................................... 14
2.5.1 Incorrect use.................................................................................................................... 14
2.6 Requirements on the part of the operator............................................................................ 15
2.6.1 Prerequisites for personnel.............................................................................................. 15
3Transport.............................................................................................................................. 16
4Storage, shutdown.............................................................................................................. 16
5Disposal ............................................................................................................................... 16
6Description of the UVR-300 / UVR-400 feeders................................................................ 17
6.1 Overview of UVR-300 / UVR-400 feeder ............................................................................. 18
6.1.1 Rear panel/connections................................................................................................... 19
6.2 Overview of the controls....................................................................................................... 21
6.2.1 Overview of the front panel.............................................................................................. 21
6.3 Display of the operating states............................................................................................. 22
6.4 Special functions (potentiometer) ........................................................................................ 23
6.5 Technical data for the universal feeder................................................................................ 24
6.5.1 Technical data for the UVR-300 universal feeder............................................................ 24
6.5.2 Technical data for the UVR-400 universal feeder............................................................ 25
6.6 Setup and connection of the devices................................................................................... 26
6.6.1 Requirements for the installation site............................................................................... 26
6.6.2 Example for a connection diagram .................................................................................. 27
6.6.3 Connections on the universal feeder............................................................................... 28
6.7 Permitted devices in combination with the universal feeder................................................ 31
6.8 Cleaning the devices............................................................................................................ 33
7Converting the universal feeder ........................................................................................ 34
7.1.1 Conversion set for M3 - M8 (preferably for UVR-300)..................................................... 34
7.1.2 Conversion set for UVR-400 (M10, M12 and Ø 10.8) ..................................................... 35
7.2 Carrying out the conversion ................................................................................................. 36
7.3 Adjusting the step width ....................................................................................................... 37
7.4 Replacing the connection piece for the stud feed hose (M3 - M8) ...................................... 38
7.5 Replacing the outlet rail and rotating the stud retainer ........................................................ 40

4 Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik
7.6 Replacing the limit stop distance plate................................................................................. 43
7.7 Differing work steps for UVR-400......................................................................................... 44
7.8 Adjusting the universal feeder.............................................................................................. 49
7.8.1 Adjusting the blow air regulator ....................................................................................... 49
7.8.2 Adjusting the blow-off nozzles......................................................................................... 50
7.8.3 Adjusting the transport speed of the weld studs.............................................................. 51
7.8.4 Readjusting the limit switch.............................................................................................. 52
8Preparing the devices for the welding operation............................................................. 53
8.1 Starting the automatic system and carrying out welding ..................................................... 54
8.1.1 Refilling the feeder during operation................................................................................ 56
8.2 Switching off the universal feeder........................................................................................ 56
9Maintenance and repair...................................................................................................... 57
9.1 Eliminating malfunctions at the universal feeder.................................................................. 57
10 Service.................................................................................................................................. 59
11 Warranty conditions............................................................................................................ 59
12 Spare and wear parts.......................................................................................................... 60
12.1 Feeder conversion set (M3 - M8)......................................................................................... 60
12.2 Individual parts for the UVR-400 conversion set (M10, M12 and Ø 10.8)........................... 62

Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik 5
1 General information
These operating instructions contain important information and rules for the operation
of your devices. Keep the operating instructions in a readily accessible location close to
your devices.
The term 'Devices' in the operating instructions refers to the UVR-300 and UVR-400
universal feeders.
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:
Universal feeder UVR-300
Universal feeder UVR-400
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.

6 Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik
Conformity declaration –Universal Feeder

Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik 7
1.4 Manufacturer
The manufacturer of the devices is:
Heinz Soyer Bolzenschweißtechnik GmbH
Inninger Straße 14
82237 Wörthsee
Phone: [phone]
Fax: [phone]
Email: [e-mail]
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

8 Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik
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 recognised safety requirements.
To achieve the greatest possible 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
Imminent danger leading to severe injuries or death.
Potentially dangerous situation that may lead to severe
injuries or death.
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: Risk of electric
shock.
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 UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik 9
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.
Protective devices must not be manipulated or disabled. Protective devices
include, for example, housing and housing cover, fuses or power switches.
If protective devices have to be removed for maintenance work, the device
may only be switched on again when all protective devices are installed and
their functionality has been checked.
Starting the device with faulty protective devices is not permitted. Faulty
protective devices must be repaired or replaced immediately. Unintentional
operation by third parties must be prevented.

10 Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik
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 protective devices have to be removed for maintenance work, the device
must only be switched on again when all protective 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. These 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.
Explosion hazard due to inappropriate installation location in a potentially
explosive atmosphere
The device is not designed for use in potentially explosive zones.
The device must not be installed and operated in potentially explosive
atmospheres.

Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik 11
Risk 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 that they have cooled down.
Do not hold the gun in the welding area.
Risk of burns from hot welding spatter
Dangerous welding spatter can occur during the welding process.
Always use personal protective equipment.
Fire hazard from hot welding spatter
Welding spatter or hot workpieces produced during the welding process can result in
fire hazard.
Do not store combustible or highly inflammable materials in the welding area.

12 Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik
2.3 Safety information for universal feeder UVR-300 / UVR-400
In addition to the general safety information in these instructions, the following safety
information applies to handling the devices:
Risk due to accelerated welding studs
The welding studs are transported using compressed air and are therefore greatly
accelerated.
Always ensure that the stud feed hose is intact.
Before each system start, check that the stud feed hoseis correctly inserted
on both sides, into the feeding unit (feeder) and the gun or welding head.
Only use stud feed hoses from Soyer GmbH.
Never bridge the safety pressure switch at the cover hood (do nottrigger the
switch if the protective hood has been removed).
Do not carry out a functional check when the cover hood is opened and the
compressed air is connected.
Regularly check that the safety interlock at the stud feed hose connection
piece moves smoothly (connecting piece M3 - M8).
Only ever use system parts which are matched to the studdiameter to be
transported (see chapter “7 Converting the universal feeder” on page 34).
Stud feed malfunctions due to misalignment
In the feeder, a few screws are marked red (see the
example on the right). If these screws become loose,
the feeder must be readjusted at the factory.
Do not loosen these screws.
Notes regarding compressed air
Only use dry and cleaned compressed air as energy source.

Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik 13
2.4 Personal protective equipment
It is recommended to wear personal protective equipment when working with the stud
welding system and universal feeder.
Danger due to a lack of or incorrect PPE
During stud welding, there is a risk of burns, especially due to hot welding spatter.
The formation of strong electric arcs can also cause a glare hazard.
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
Welding spatters and a flash of light occur during
welding. In order to protect your eyes, 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. In
that case, wear appropriate hearing protection.

14 Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik
2.5 Intended use of the stud welding systems
The devices (universal feeders UVR-300 and UVR-400) described here require
additional components for automatic operation.
Stud welding device with feeder interface, e.g. BMS-9 Automatic
Automatic stud welding gun or head
Typical application areas for the automatic feed of welding fasteners are as follows:
Stationary robotic stud welding machines
Stationary CNC stud welding machines
Mobile hand-operated stud welding machines
For the sake of simplicity, only a hand-operated stud welding system is
described in these operating instructions.
For example, in connection with the energy source BMS-9 Automatic and the stud
welding gun PS-3A, the studs can be fed into the gun automatically using compressed
air.
These operating instructions and the declaration of conformity only apply if the
named devices are used together as described in these operating instructions.
In automatic mode, the universal feeders may only be operated with the accessories
described in these instructions.
Operation of the stud welding system must be in accordance with the technical data.
Special studs or diameters upon request.
The devices described here can also be operated separately in other
combinations. In case of using a stationary robotic or CNC stud welding
machine, the respective operating instructions of the devices must also be
observed.
2.5.1 Incorrect use
Any use of the devices deviating from the intended use is considered improper use.
Non-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.

Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik 15
2.6 Requirements on the part of the operator
The operator of the devices must ensure that the preconditions described in this
operating manual regarding 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 devices.
These operating instructions must be stored in the vicinity of the device.
The operator of the devices must ensure that all protective 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 maintain the qualification, safety training must be carried out at least once a year. In
the event of malfunction or for maintenance, specially trained personnel or the
manufacturer must be consulted, if necessary.
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 have 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
The following generally applies:
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®.

16 Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik
3 Transport
When transporting the devices, make sure they cannot be damaged. Use appropriate
packaging to 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.

Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik 17
6 Description of the UVR-300 / UVR-400 feeders
The UVR-300 and UVR-400 universal feeders
allow weld studs of different diameters to be
loaded rapidly and fully automatically into the
welding gun or welding head. Time-consuming
conversion or adjustments to other stud
diameters are not required.
A vibration drive transmits vibrations to the
feeder bowl. The studs move clockwise from the
base of the feeder bowl to the stud escapement
via spiral-shaped steps travelling upwards.
The feeder bowl is fitted with a step width
adjustment to strip off studs lying on top of one another, or to separate studs sitting next
to one another. After the studs have run through the separating device, the individual
studs move into the outlet rail through the vibration and hang in a vertical position.
When transporting tapped studs, it cannot be ruled out that the ignition tip in the internal
thread may become entangled in a preceding or subsequent tapped stud. The air flow
of an air nozzle separates the entangled tapped studs before they are fed into an
inclined plane where they are transported to the slide.
A compressed air cylinder moves the stud retainer, which serves to hold the studs,
under a hose retainer. Compressed air is fed through a blow air nozzle which blows the
studs and moves them into the stud welding gun or the welding head via the stud feed
hose.
The feeder intensity can be adjusted via a potentiometer. This is controlled via a control
panel with membrane keypad. LED displays and signal transmitters on the stud
escapement enable a regulated function in both continuous and automatic mode.
■ Automatic feed
In connection with e.g. the PS-3A stud welding gun and an energy source with feeder
interface, the studs can be fed into the gun automatically using compressed air.

18 Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik
6.1 Overview of UVR-300 / UVR-400 feeder
Complete overview
Figure 1: Overview of UVR-300 feeder (UVR-400 is similar)
Item
Designation
a
Protective hood
b
Function keys of the universal feeder (see “6.2.1 Overview of the front
panel” from page 21)
c
Both sides, locking screws for the protective hood
d
Mains switch for turning the device on/off
e
Feed opening for the stud feed hose
f
Safety switch to disconnect the compressed air when the protective hood
is not attached.
The safety switch must not be bypassed!

Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik 19
6.1.1 Rear panel/connections
Figure 2: Overview of the device back panel
Item
Designation
a
Blow air regulator
b
Type plate
c
Main air connection
Observe the maximum permitted pressure.
d
Hose package with all lines and hoses for connection to the stud welding
device and with the mains plug for the feeder.

20 Operating instructions UVR-300/UVR-400 | Heinz Soyer Bolzenschweißtechnik
Transport area
Figure 3: Overview of the transport area UVR-300 (UVR-400 is similar)
Item
Designation
a
Feeder bowl with welding studs
b
Connection piece for the stud feed hose (replaceable part)
c
Outlet rail (replaceable part)
d
Blow-off nozzles to separate studs lying on top of one another
e
Hold-down plate
f
Stud retainer