Operators Manual - Image Industries
Contents
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4. Used to call attention to immediate hazards which if not avoided will resultin immediate Serious personal injury or loss of life Used to call attention to potential hazards WARNING which could result in personal injury or lost of life Used to call attention to hazards which could CAUTION result in minor personal injury Section 2 Installation KO Location The power supply should be located On a flat level floor e Near the work area to limit welding cable length shorter lengths are preferred In a dry area away from moisture Placed to protect it from grinding dust and other contaminates To provide min 12 clearance on all sides for cooling Such that the leg openings and the area between the legs is not blocked again for cooling Electrical ALL Electrical connections should be made by a properly certified electrical professional It is recommended that a line disconnect switch be installed in the input circuit to the welding power source This provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever it is necessary to perform any work on it Before making the electrical input connections to the welding power source machinery lockout procedures should be employed If the connection is to be made from a line disconnect switch the switch should be padlocked in the open position If the connection is made from a fuse box remove t
5. 4 Refer to ANSI ASC Standard Z49 1 see listing on next page for specific ventilation recommendations CYLINDER HANDLING Cylinders if mishandled can rupture and violently release gas Sudden rupture of cylinder valve or relief device can injure or kill Therefore 1 2 3 4 5 Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder Do not use adaptors Maintain hoses and fittings in good condition Always secure cylinders in an upright position by chain or strap to suitable hand trucks undercarriages benches walls post or racks Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit When not in use keep cylinder valves closed Have valve protection cap in place if regulator is not connected Secure and move cylinders by using suitable hand trucks Avoid rough handling of cylinders Locate cylinders away from heat sparks and flames Never strike an arc on a cylinder For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 J efferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the installation troubleshooting an
6. Electrical Arrangements Arc stud welding of aluminum should be performed with direct current electrode positive DCEP This is the opposite of standard stud welding For aluminum the gun should be connected to the RED output terminal and the ground should be connected to the BLACK output terminal Stud Welding using DCEP direct current electrode positive SHOULD NOT be A CAUTION used in multi gun mode If you have a multi gun unit and need to weld aluminum or other material studs using DCEP only connect 1 gun NEVER MIX electrode positive DCEP and electrode negative DCEN on this stud welder Shielding Gas for Aluminum Shielding gas for arc stud welding and drawn arc capacitor discharge stud welding is generally argon of at least 99 95 percent purity Helium may be used with large studs to take advantage of the higher arc energy required for magnesium The gas should be directed to the weld area with an adaptor foot and permitted to flow only while the gun is held against the work in the welding position Generally 10ft hr 91 min is a good starting point for gas flow however the shielding gas flow rates recommended by the stud manufacturer should be used Other Materials On a moderate scale stud welding is being done commercially on various brass bronze nickel copper and nickel chromium iron alloys These applications are usually very special ones requiring careful evaluation to determine suitability of design Nickel
7. This is the post flow phase By pressing the scroll down button the display changes to allow programming the pre flow and post flow timing The upper rotary knob controls pre flow time while the lower rotary knob controls post flow time These times can be adjusted from 0 seconds off to a maximum B Te Mode time of 2 seconds A setting of 0 5 seconds for both pre and post flow works well for many stud welding applications If multiple guns are installed the gas mode pre flow and post flow values are set individually for each gun Adjust the pre and post flow times to what works best for a particular application If the lower left corner of the Gas Mode screen displays the i lock symbol then the Gas Mode can not be changed without entering the unlocking code See Code Section for details on entering the code When the gas flow is enabled the flow enabled LED will be lit Note this LED shows the status for the active gun If this is a multi gun unit the LED will show the status of only the gun number shown on the display Remember pulling the gun trigger or pressing the gun control button will cause the display to show the information for that gun DATA RECORDER MODULE This module preforms two functions 1 It can output a data stream to a printer laptop or any other device capable of capturing serial ASCII data 2 Accepts preprogrammed limits for time and current The unit then compares the weld results to those limits If the
8. Longer do greater than or equal to 480 amps and less than or equal to 550 amps Any weld which was outside this range would halt the welder and display an error so corrective action could be taken HS For Pere Once in the Limit Current screen pressing the W scroll down button displays the Limit Time screen The Upper and Lower Limits for weld time operate similarly to those for current By reducing the time values to a minimum the display will eventually show that limit is OFF As with the H Fop Meee Current Limits the Upper Time Limit can not be below the Upper Time Limit The welder will adjust the Limits if the user attempts to defeat this This provides a total of 4 limits Any number of limits from none to all 4 can be active at one time When one or more of the 4 limits is active then the active LED on the Data Recorder Module will be lit This light shows the status of the data recorder for the active gun Pressing W scroll down again displays the time date and printer speed screen Details on adjusting these items are on the next page Detected Errors If the data recorder module detects an error i e one of the 4 limits has not been met the display will show an error It will only show an error for the first limit that is not met If there is a condition where more than one limit is not met multiple errors will NOT be displayed When an error is displayed the unit will not weld on that output again until the error has b
9. Speed BAUD Rate lt gt These menu trees are for optional modules Each tree can be brought up on the display screen by pressing the corresponding control button on the optional module With multiple guns there are no additional menu trees However the settings in the standard menu tree and optional menu trees can be set differently for each gun 37
10. are several different stud welding processes that this welder can perform Be sure that your stud gun is set up properly for the process you intend to use See Section 5 for discussion of different processes Position the gun against the work Press down on the stud gun to make sure the ferrule or spark shield sits firmly against the work While holding the gun in position pull the trigger The weld will initiate gas flow will start if the gas module is enabled and complete Continue to hold the gun against the work for 1 2 sec to allow the molten metal to cool Pull the gun off of the stud This completes a weld sequence OTHER CONVENIENCE FEATURES Accessing using or understanding these features is not necessary for successful stud welding These features increase the functionality convenience and ease of use of the stud welder AUTO WELD This feature simplifies set up for the less experienced operator and minimizes adjustments required for changes in base stud material and setup This mode is called Auto Weld since it allows the operator to set up the power supply based on the fastener size and type rather than requiring the operator to know correct time and current settings Aubomabic Gud Size Ja Stud Material This feature is activated by the Auto Weld button on the front panel The green LED in the Auto Weld button will light indicating the power supply is in Auto Weld mode The upper rotary knob selects the fast
11. is then lifted from the stud and the ferrule is broken off The Drawn Arc Stud Welding DASW process is the most robust stud welding process It can weld effectively and reliably under a broad range of conditions The flux ferrule combination also provides the greatest weld penetration into the base material Of the available arc processes this should be the designer s first choice The other processes are typically selected as a trade off for some factor 24 Section 5 Special Welding Gas Arc Stud Welding GASW uses shielding gas This process is similar to the DASW with a few exceptions The stud is loaded into the chuck There is a spark shield used for gas delivery in place of the ferrule grip and the ferrule The gun is properly positioned The trigger is pulled and gas pre flow begins When the pre flow time has elapsed the automatic weld cycle begins and follows the same sequence as DASW At the end of the weld cycle gas post flow begins After the gas post flow concludes the entire weld cycle is complete and the gun can be removed While the actual weld arc times are similar to DASW there is typically gas pre flow and post flow times which add to the overall time per weld Since no ferrule is required handling and cleanup are reduced The absence of a ferrule has pros and cons On the plus side it can reduce the cost of the studs It also lends itself to automated processes since the handling operations are reduced On the minus
12. options Option 1 All Locked All Features are locked and require the entry of a user code to adjust values Option 2 All Unlocked No Features are locked Option 3 Selective Locking Some Features are locked and require entry of a user code to adjust values SELECTIVE FEATURE LOCKING The first item that comes up under Selective Feature Locking is the Feahure Lock iva Maintenance Counter Turning the lower rotary knob will change the mm qua Lock ine Maintenance Counter Lock from Locked to Unlocked and back again Locker b Eor Hert To adjust other features press the gt scroll right button The following features will come up in order if available Maint Counter Pilot Arc Hammer Mode Language Gas Mode Limits Preset Error Each feature can be individually locked or unlocked to prevent unauthorized adjustment Some features are optional If that optional module is not installed you will not see the choice to lock unlock that feature 15 Normal Operation ERROR REPORTING _ Starting at the home screen press the W scroll down button 6 times to Weld Errors buri reach the error reporting screen If the last row of the Error Screen RerorLind Or displays the lock symbol the feature can not be reset with out entering the unlocking code See Code Section for detail on entering the code To unlock this screen you must enter the user password This feature only applies to the manual stud welding mode In the auto
13. recommendations MOVING PARTS CAN CAUSE INJURY Electric fan can start at any time without warning and cause severe injury therefore 1 Always disconnect electrical power prior to service to prevent the fan from starting unexpectedly 2 Keep all doors panels covers and guards closed and securely in place 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 Keep hands hair loose clothing and tools away from moving parts 5 Reinstall panels or guards and close doors when servicing is finished and before re energizing welder ADDITIONAL SAFETY INFORMATION For more information on safe practices for electric arc welding refer to the following publications The following publications which are available form the American Welding Society 550 N W Lei uene Road Miami FL 33126 are recommended to you 1 ANSI ASC 249 1 Safety in Welding and Cutting 2 AWS C5 1 Recommended Practices for Plasma Arc Welding 3 AWS C5 6 Recommended Practices for Gas Metal Arc Welding 4 AWS SP Safe Practices Reprint Welding Handbook 5 ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances This symbol appearing throughout this manual means ATTENTION BE ALERT Your safety is involved The following definitions apply to DANGER WARNING CAUTION found throughout this manual
14. repaired in accordance with the instructions provided This equipment must be checked periodically Defective equipment should not be used Parts that are broken missing worn distorted or contaminated should be replaced immediately Should such repair or replacement become necessary the manufacturer recommends that a tele phone or written request for service advice be made to the Authorized Distributer from whom purchased This equipment or any of it s parts should not be altered without the prior written approval of the manufacturer The user of this equipment shall have the sole responsibility for any malfunction which results from improper use faulty maintenance damage improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer Section 1 Safety PALZ WARNING These Safety Precautions are for your protection They summarize precautionary information from the references listed in the Additional Safety Information section Before performing any installation or operating procedures be sure to read and follow the safety precautions listed below as well as all other manuals material safety data sheets labels etc Failure to observe Safety Precautions can result in injury or death K PROTECT YOURSELF AND OTHERS Some welding cutting and gouging processes are noisy and require ear protection The arc like the sun emits ultraviolet UV and other radiat
15. side there is less fillet control This can create difficulties when welding in any direction other than down handed Additionally shielding gas does not typically offer as deep of penetration as flux Short cycle Stud Welding SCSW This process is similar to DASW except no flux load or ferrule is used Instead of a ferrule grip and ferrule a spark shield is used The process sequence is the same as for DASW Because there is no flux or shielding gas this process typically exhibits porosity The fundamental difference between this process and DASW is that high currents and short weld times are used The short weld time minimizes the effect of the porosity This is the least expensive process in that no ferrule or gas is utilized This process also uses the shortest weld times Short weld times are used to minimizes the porosity from the unshielded atmosphere Because of the porosity inherent in this process it is generally not a recommended process Factors such as thin sheet metal insignificant strength requirements significant cost constraints and very high installation speed requirements may over ride weld quality and this process may be chosen Gas Arc Short Cycle Stud Welding GASCSW This process combines GASW and SCSW This uses the short cycle process but adds shielding gas to eliminate the effects of porosity By reducing the weld time versus GASW there is better fillet control However weld current requirements are increased and can r
16. to the welder Main Transformer Jumper Links All units from the factory are pre jumpered to the highest selectable voltage Always verify jumper set tings before connecting electrical power to any device Facing the front of the welder the jumper links are located on the right hand side at the rear of the unit on a 12 position barrier strip Input Contactor Control Transformer Jumper Links 12 Position Barrier Strip Control Transformer GND PE Green or Green With Control Transformer Fuse Yellow Stripe s 460 Volt Jumper Configuration The extra jumper L ny eee convienent stor O lt O age 230 Volt Jumper Configuration O E o O ISS n rr AU AZ Section 2 Installation KO Control Transformer Similar to the main transformer the control transformer also has configurable jumper links These are located directly on the control transformer on the side nearest the front of the unit The control transformer is located at the top of the axillary module see diagram on preceeding page which also houses the contactor and the main transformer jumper block There are two wires connected t
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18. Diagram Upper Rotary Knob Flow Enabled Geer Memory Presets 8 Scroll Up S H k d Lower Rotary Active LED Data Module Control Knob Serial Port Ge Lock Auto Weld Ss Gei gt e Scroll Down AN 4 4 4 Auto Man Manual Feed reeg ZAN Manual Weld ELE a Gun 1 Gun 2 Gun 3 Gun 4 0 Power Switch Some features shown are optional Screen Conventions helder Fure Line 1 Welder Function ta Lire SI Line 2 Data Line Controlled by Upper Rotary Knob ta Lire SA Line 3 Data Line Controlled by Lower Rotary Knob Information Line 4 Information Maintenance Required more info on next screen locked unlocked Display Backlighting To extend display life the backlight will turn off after a few minutes This is normal The next button push or knob turn will light the backlight again Home Screen The Home screen is either the Normal Operaion screen or the Auto weld screen depending on the selected mode To weld the home screen must be show
19. ILM001E June 2000 Price 5 50 USD Alice anual Drawn Arc Stud Welding Power Source SW1200 amp SW2000 OCG BE SURE THIS INFORMATION REACHES THE OPERATOR EXTRA COPIES ARE AVAILABLE THROUGH YOUR SUPPLIER THESE INSTRUCTIONS ARE FOR EXPERIENCED OPERATORS If you are not fully familiar with the C A U T O N principles of operation and safe practices for arc welding equipment we urge you to read AWS SP Safe Practices available from the American Welding Society Do NOT permit untrained persons to install operate or maintain this equipment Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions If you do not fully understand these instructions contact your supplier for further information Be sure to read the Safety Precautions before installing or operating this equipment IER Contents SECTION 1 Safety Precautions 3 SECTION 2 Set Up 7 SECTION 3 Normal Operation Basic 10 Auto Weld 12 Advanced Features 14 SECTION 4 Optional Features Preset Memory 18 Gas 20 Data Recorder 20 Multi Gun 23 SECTION 5 Special Techniques 24 SECTION 6 Trouble Shooting 29 SECTION 7 System Maintenance 32 SECTION 8 Schematic Diagram 33 SECTION 9 Part List 34 APPENDIX A Menu Trees 36 USERS RESPONSIBILITY This equipment will perform in conformity with the description contained in this manual and accompanying labels and or inserts when installed maintained and
20. Mutli gun Auto Feed User Interface PAE1203 7 PAH017 Items Not Shown 43 Multi gun Ground Jumper Link PAE80 4 4 Weld Output Filter PAE801 Items Not Shown Cable 1200A Rectifier to Choke CW3KK 1 3 CW5LL 1 3 51 Multi gun Autofeed Aux Power Harness 52 i 4 5 6 7 8 9 B Cable 1200A Choke to Ground CW34K 2 3 W5ML 2 3 2 Incoming Power Cord Grip Cable 1200A Rectifier to Gun CW 34K 3 W 5ML 3 53 Rear Sheet Metal Hole Plug Control Panel Retention Straps PAM71 4 Ribbon Cable Main PCB to MG PCB 4 4 55 Power Cable Main PCB to MG PCB 56 Autofeed Solenoid Harness 52 EA 23 48 BEE EE ER BEE s 50 ee A 35 Appendix A Menu Tree STANDARD MENU TREE Scroll Right Home gt Normal Operate or P autoweld lt P This is a quick reference to find a specific welder Actual function This is the basic menu tree that comes standard with all power supplies gt Scroll Up Scroll Down lt gt lt gt Maintenance gt gt Life time Tracker Welds lt lt gt Pilot Arc Skipped if in Automatic Mode A A Y Y Hammer Mode
21. N2 Additionally the LED above the Gun2 Control Button will light up To change any weld parameter for a particular gun you must first select that gun s control button Alternatively you can air trigger that gun as long as the Home screen is currently displayed Auto Feed High Level Control Because of the advanced nature of these features they are not covered in this document Should your welder be equipped with any of these features a separate document will accompany your welder For any questions contact your authorized dealer 23 Special Welding Techniques PROCESS DISCUSSIONS This section is provided to give a brief overview of different stud welding processes If you have additional questions consult your distributor for additional information or refer to the Recommended Practices for Stud Welding ANSI AWS C5 4 American Welding Society Inc General Process Discussion The arc stud welding process involves the same basic principles as any other arc welding process Application of the process consists of two steps 1 Weld heat is developed with an arc between the stud electrode and the plate work 2 The two pieces are brought into contact when the proper temperature is reached The time required to complete a weld varies with the cross sectional area of the stud For example weld time typically would be about 0 13 seconds for a 10 gage 0 134 in 2 6 mm stud and 0 92 seconds for a 7 8 in 22 mm diamet
22. To change the Cirai user code this feature MUST be unlocked To unlock this screen you must enter the user password ined The first key press must be the B button This tells the unit to expect a password The display will show a gi key symbol to indicate that it is ready to be unlocked The factory default password is 33333 Press the key numbered 3 labeled on the bottom a total of 5 times This unlocks all screens NOTE The screens relock automatically when the fh home button is pressed or when the time out returns the unit to the home screen Once this feature is unlocked a new user code can be entered First press the a button to indicate a password is being entered This must be followed by any other 5 numbered buttons number labels are below the keys in any sequence The menu will prompt the user to reenter the same password to verify the password is correct Again 16 Section 3 Normale A Eion Sot Hey User Code the 2 code key must be pressed first Once the new password is confirmed the code is changed DO NOT FORGET YOUR CODE If the R code is lost there is NO way to recover it In the event that the user code is lost the entire system memory can be erased to reset the password to the factory default See trouble shooting LANGUAGES From the home screen press the W scroll down button 8 times or the Language A scroll up button once to access the Language Screen This allows the Erap pak unit to d
23. actual weld results fall above or below those limits welding is halted to allow for corrective actions These features can be useful to companies using SPC or implementing ISO9000 or QS9000 programs 20 Section 4 Optional To access the data functions press the control button on the data module This brings up the data limit menu on the display The first screen is the current limit screen This allows the system to track weld results versus predefined current limits If the screen is locked then it must be unlocked before any values may be changed To change the Upper Current Limit use the upper rotary knob and use the lower rotary knob to adjust the Lower Current Limit If the value for that limit is continually reduced the display will show that limit as OFF and will not check against that limit The Upper Limit can not be set below the Lower Limit and the Lower Limit can not be set above the Upper Limit If you try to adjust the Lower Limit above the Upper Limit the welder will automatically increase the Upper Limit to keep it above the lower limit Similarly when the Upper Limit is reduced to the Lower Limit the system will reduce the Lower Limit to keep it below the Upper Limit For example the desired weld may be 500 amps Weld engineering may Limit Current GHI allow results which vary from the 500 amp target The limits might be set Curren prer See up as shown to the left This would pass any weld as acceptable that is CD pret
24. anel Once unlocked the set point is changed by the upper rotary knob This value changes by 100 s If desired this feature can be turned off by turning the knob to the left until OFF is displayed Suggested Uses This feature can be used in conjunction with preventative maintenance programs It can be used for many purposes Some suggestions might be Blowing dust out of the power supply Cleaning Servicing Stud Gun Changing Weld Chucks Total Lifetime Welds While in the maintenance screen pressing the gt scroll right button will show the number of welds since the power supply was built up to a maximum of 4 billion welds Maintenance Courter 13 Normal Operation ADVANCED FEATURES PILOT ARC Pilot arc control is an advanced topic If you do not have a good Hediust GHI understanding of the stud welding process do not adjust these values Filok urreni cj The factory default setting of 100 Amps for 0 050 seconds is sufficient for most stud welding purposes Fa lots HH H The weld sequence is broken into two phases the pilot arc phase and the main arc phase The pilot arc is typically a low current arc for a short duration that is used to establish the main arc The pilot arc allows for a smooth transition to the main arc and improves welding results Hot Plunge Pilot Arc Phase Wi K To access the Pilot Arc screen from the home screen press the W scroll down button twice If t
25. ation CU is added to the mix CO percentages range from 10 to 25 depending on the desired level of penentration Stainless steel will typically use a mix of 82 Argon and 18 C02 Other mixes are used to achieve different results Aluminum In general all plate alloys of the 1100 3000 and 5000 series are considered excellent for stud welding alloys of the 4000 and 6000 series are considered fair and the 2000 and 7000 series are considered poor Most alumi num weld studs are manufactured from 5000 series aluminum Base Metal Preparation Base metal to which studs are to be welded should be free of anodic coatings moisture or other foreign material to assure obtaining sound welds These areas may be cleaned by etching brushing with a stainless steel bristle brush scraping or grinding Prior to welding surface areas to which studs will be welded should be clean and free of foreign matter including the following 1 Paint 2 Moisture 3 Heavy oxide film 4 Oil grease indelible markings etc 5 Anodic coatings Cleaning may be accomplished by mechanical means milling stainless steel wire brushing chemical methods or 27 Special Welding Techniques both Oil grease and similar contaminants should be removed with a suitable safe solvent The use of chlorinated hydrocarbons should be avoided A heavy oxide film may require removal by chemical means Welding should take place within eight hours after cleaning
26. b u au URY ss 0 SEM JU JNI DA au pa dejep sey yun ayy lnpoui Jap4odaJ LJP ayy Ul dn yas WWI dS MO SW pjm au p 2x JALU sl ns 4 Dia au npoui Japsored BJP au ul dn yas Ywl dS UM atu pjm y P 92X ALY Sl ns 4 PJ M u a NPOW J p402 4 EI ayy u dn jas WWI dS MO JUNI pjam dU p 2x ALY Sun Dia au npoui Japsored EIED y u dn yas Wu dS Ysly yUssUNd DA BY p 2x ALY SYNS I PJ M oy Suluevop OL PUN Zou PPM OL 42AO Zou PPM OL PUN yuan PPM MO ull UWI PI AA ES ER B V au WUT PISAA E B H MOT USD WT PPM ysiH Juaand WUT PPM 4aquinn 4o443 29 Trouble Shooting AWA NPuod IER poog sl 9494 duns aye g yd puNo Is J294 yed punoi3 Jood 348 31n2 ysey pinb jews e s ysnf Lew no A ue umegzurew JO 1u8li j njss p ns Yl UNS np w Sunue s MOY Ju un2 o Jol4d y4OM ayy 0 q JOU sI Japan uU HO su pris ay u uA p sne2 aq uep DJe ue BUIMeIP yNoyyM adaI1d 440M Y O SADS I leq sp 4o prs au lle9id Dous aa eee PUB How aU JO JO I JOU PIP sey MOY JUN Jaye un a2ad JOM dU O pn3s au YI JOU s op ung Se pnas y u uA pasned AE2d0 s sty 9 382d Bunuoday 40449 JJO UNJ 9w PI A se Du yl ung sonpay uno pris asnipy ue o s sn ASA BULIM 821 32 UE KHA 91 a8eq uniod i Josue Yo win auup PJBM aseaJDU YI uns sonpay uno pnis 3sn py ue o s sn
27. d maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance work inside a power source disconnect the power source from the incoming electrical power 3 Maintain cables grounding wire connections power cord and power supply in safe working order Do not operate any equipment in faulty condition 4 Do notabuse any equipment or accessories Keep equipment away from heat sources such as furnaces wet conditions such as water puddles and inclement weather oil or grease corrosive atmospheres 5 Keep all safety devices and cabinet covers in position and in good repair 6 Use equipment only for its intended purpose Do not modify it in any manner ELECTRICALLY POWERED EQUIPMENT Faulty or improperly electrified equipment can cause injury or death Therefore 1 Always have qualified personnel perform the installation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any work inside a power source disconnect the power source from the incoming electrical power using the disconnect switch at the fuse box before working on the equipment 3 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacture s recommendations 4 Ground the equipmentin accordance with the U S National Electrical Code and the manufacturer s
28. ects which are unknown 3 Welders should use the following procedures to minimize exposure to EMF A Route the electrode and work cables together Secure them with tape when possible B Never coil the torch or work cable around your body C Do not place your body between the torch and work cables Route cables on the same side of your body D Connect the work cable to the work piece as close as possible to the area being welded E Keep welding power source and cables as far away from your body as possible FUMES AND GASES Fumes and gases can cause discomfort or harm particularly in confined spaces Do not breathe fumes and gases Shielding gases can cause asphyxiation Therefore 1 Always provide adequate ventilation in the work area by natural or mechanical means Do notweld cut or gouge on materials such as galvanized steel stainless steel copper zinc lead beryllium or cadmium unless positive mechanical ventilation is provided Do not breathe fumes from these materials 2 Do notoperate near degreasing and spraying operations The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene a highly toxic gas and other irritant gasses 3 If your develop momentary eye nose or throat irritation while operating this is an indication that ventilation is not adequate Stop work and take necessary steps to improve ventilation in the work areas Do not continue to operate if physical discomfort persists
29. een cleared reset Clearing Errors To clear an error press the f reset button on the front panel If the error screen is locked it must be unlocked before the error can be cleared 21 Optional Features Adjusting the Time and Date Press the bp scroll right button to activate the time change mode The hour and AM PM will start to flash Either rotary knob will adjust the hour This setting also adjusts AM PM by adjusting the hour before or after 12 00 Press the i gt scroll right button again and the minute will flash Again either rotary knob will adjust the minute By pressing the gt scroll right button again the month will start to flash Either rotary knob will adjust the month up or down Repeat this procedure to adjust the day and year Pressing the W scroll down button again brings up the Printer Speed BAUD Rate screen Capturing Output Data Once installed the data recorder module will ALWAYS report weld data If weld data is not required the printer port can be left unconnected The data is not saved in any way and must be captured by some device after every weld The 9 pin male connector on the front panel must be connected to an appropriate device to capture data A serial printer verify with printer manufacturer with a standard serial cable or a laptop running a terminal program with a null modem cable can be used to capture output Changing Data Rate The top rotary knob will change the welder s out
30. ener diameter Choices are NT stands for No Thread FT for 1 4 5 16 3 8 1 2 5 8 for 2000 Amp only 3 4 7 8 and 1 Full Thread PD for Pitch Diameter mm 8mm 10mm 12mm 16mm for 2000 Amp only 20mm and 24mm The lower control knob selects the stud material Choices are STEEL for low carbon steels C1008 C1018 ALLOY for stainless steels The operator then welds normally The system measures parameters during the weld cycle and adjusts the weld to attempt to achieve optimum weld results The Auto Weld feature is not intended to solve all welding problems It has been designed to weld well in typical applications It can compensate for variations in materials and variations in the stud gun lift settings THE AUTO WELD MODE ONLY WORKS WHEN WELDING DOWN HAND That is with the stud gun pointed towards the floor Welding in other positions will require the manual mode and adjustments to parameters The auto settings also assume that for studs 1 2 12mm and larger that the stud gun is using a plunge dampener If the Auto Weld mode is not providing satisfactory weld results use the manual mode and set the weld parameters to achieve your desired results 12 Section 3 Normal fejti REVIEW LAST WELD RESULTS This feature confirms that the weld results are consistent with the settings keld Resul hs HLHI that have been selected To see the actual time and current results of the UCL Curreri L last weld press the p gt scroll right button This s
31. equire a larger power supply The reduced weld time also reduces weld penetration This can be a plus for arc welding onto thinner gauge sheet metal Because shielding gas is used the installed cost is greater than SCSW but porosity is eliminated SPECIAL TECHNIQUE DISCUSSION Low Carbon Steel Low carbon mild steels can be stud welded with no major metallurgical problems The upper carbon limit for steel to be arc stud welded without preheat is 0 30 percent If work sections are relatively thin for the stud diameters being welded the carbon limit may be somewhat higher because of the decreased cooling effect of the work If the section to which the stud is to be welded is relatively thick stud welding of steel with more than 0 30 25 Special Welding Techniques percent carbon using normal techniques and without preheat must be evaluated The most important factor regarding work section thickness is that the material must be heavy enough to permit welding the studs without melt through Medium Carbon Steel If medium carbon steels are to be stud welded it is imperative that preheat be used to prevent cracking in the heat affected zones In some instances a combination of preheating and postheating after welding is recom mended In the case of tough alloy steels either preheating or postheating may be used to obtain satisfactory results In cases where the welded assemblies are to be heat treated for hardening after the welding operatio
32. er Multi gun Steering SCR Harness anking Plate ssembly Sheet Metal Right Side Multigun SCR Support Pan A Arm Left Front Right Rear A Arm Right Front Left Rear Chassis Leg Front Sheet Metal Assembly Rear Sheet Metal Auxillary Module Tray Isolation Shoulder Washer s Ei ba a gt D be D vo a a a w 5 a ing Plate a 5 y w 5 2 E S T SS Iw a m 5 A 9 S 5 fei AE501 AE500 AE600 d x S 3 oO 2 an ks H 0 V w wn Lo Lol Gol Go STSTSTsIzTz GEIER elei lei i SIE 2 aljajala 2 3 S BR alala a olols O lt lt Sisto 3 x sls s s zl g s zl IS lt 2 2 Slo o zlziguzl ig ajala a a cfc ola 2 3 2 e e el 13 IF gt 2 gt d gt E gt alo gt a z v Ee 5 Ss 51s 3 ou pee ke a sm oO GILLI Siok oO We Jo SR o oO na Si D 3 3 5 Ur N i 9 LA LA LA Ww wt ou a a gt V Lo 7 Cooling Fan Assembly 37 Data Recorder Module Cooling Fan Assembly a I Gas Control Module SET CCLI7ORFR i Gas Vale PNVA242 Main PCB right side Gas Valve Station Plug PNMA PLUG Multigun Autofeed Board Left Side Autofeed Air Manifold PNMB 4 User Interface Assembly Autofeed Valve Station Plug PNMB PLUG Rotary Knobs Multi gun Autofeed Blanking Plate PAS130A Ribbon Cable to Main Board 41 Multi gun User Interface PAE1202 25 Power Switch
33. er stud There are 4 basic Arc Stud Welding Processes 1 Standard Drawn Arc Stud Welding DASW This Process uses a flux load embedded into the weld stud and a sacrificial ceramic ferrule for shielding 2 Gas Arc Stud Welding GASW This process uses no flux load and no ceramic ferrule It does rely on shielding gas to protect the weld zone 3 Short Cycle Stud Welding SCSW This process uses no flux ferrule or shielding gas Welds are achieved with high currents and short weld times Welds of this nature are subject to porosity 4 Gas Arc Short Cycle Stud Welding GASCSW This weld uses high current and short weld times similar to SCSW but adds shielding gas to prevent porosity Standard Drawn Arc Stud Welding DASW with ferrule The stud is loaded into the stud gun or weld head chucking mechanism the ferrule also known as an arc shield is placed into the ferrule grip over the end of the stud and the gun is properly positioned for welding The trigger is then depressed starting the automatic welding cycle A lift mechanism within the body of the gun is energized This lifts the stud off the work and at the same time creates an arc The end of the stud and part of the work piece are melted by the arc When the preset arc period is completed the welding current is automatically shut off and the lift mechanism is de energized by the control unit The gun plunges the stud into the molten pool on the work to complete the weld The gun
34. he fuses from the box and padlock the cover in the closed position If the unit is connected to a circuit breaker or other disconnecting device without locking facilities attach a red tag to the device to warn others that the circuit is being worked on Connect the input conductors to the welding power source before making connections to the three phase input voltage Check the input voltage jumper link arrangement on the main weld transformer and control transformer to make sure the transformer is connected correctly for the incoming line voltage The ground terminal is connected to the welding power supply frame and is for grounding purposes only Do not connect a conductor from the ground terminal to any of the line terminals This will result in an electrically energized HOT power supply frame Always connect the input grounding conductor to the long 1 4 20 stud on the base panel first This stud will already have green or green with yellow stripe wires connected to it Fusing Cable Recommendations SW 1200 Guage SW2000 Guage All Disconnect Fuses should 230 V 100A 1 150A 1 0 be delay type 460 V 50A 4 75A 2 The red black and white wires on the incoming cable do not need a termination The green or green with yellow stripe ground wire will need a ring terminal with a 1 4 clearance hole Installation amp Set Up SETTING JUMPER LINKS There are several jumper links that must be set before connecting electrical power
35. he last row of the Pilot Arc screen displays the i lock symbol then the pilot arc can not be changed without entering the unlocking code See Code Section for details on entering the code Current Amps Main Arc Phase The pilot arc is adjusted the same way as the main arc See Normal Operation A time value of 0 disables the pilot arc phase of the weld The display will show OFF when a time value of 0 is selected HAMMER MODE SS From the home screen press the Harmer Mode D W scroll down button 3 times to access the Hammer Mode screen This Hanmer zs OH mode is most useful when welding on dirty rusty mill scale or painted Harper Card de surfaces painted surfaces require a special stud The system automatically detects ground If ground is not found the gun lifts and plunges to break through the scale or paint It will repeat this lift plunge hammer sequence until ground is detected at which point the stud will weld After the set number of hammers the system stops and returns to the ready state If the lower left corner of the Hammer Mode screen displays the H lock symbol then the Hammer Mode can not be changed without entering the unlocking code See Code Section for details on entering the code The upper rotary knob cycles the hammer mode between on and off The lower rotary knob adjusts the number of hammers between 1 and 15 hammers a setting of 5 10 is usually sufficient Lift Check If the ham
36. hows the actual measured values for main weld current and main weld time for the previous weld Pressing the gt scroll right button again returns you to the Home screen When using Auto Weld data is reported in Amps and Energy Watt e Seconds Actual Note Due to many factors these values may not EXACTLY match your settings Results within a few percent of your settings are normal MAINTENANCE COUNTER This feature allows the operator shop supervisor or maintenance Hainkbernaree Courier department to track service intervals Tracking service intervals allows maintenance to be skipped when not required or calls attention to maintenance requirements when they are due From the Home Screen pressing the W scroll down button once displays the maintenance screen This screen shows the actual welds since the last maintenance interval This also shows the maintenance alert set point When the actual welds since the last maintenance interval are greater than or equal to the maintenance alert set point the message Maintenance flashes across the bottom line of the Home Screen When this occurs the counter can be reset from the Maintenance Screen If the last row of the Maintenance Screen displays the H lock symbol the feature can not be reset with out entering the unlocking code See Code Section for detail on entering the code Once the screen is unlocked the alert can be cleared by pressing the reset button f on the front p
37. iaoid O adk Aejaq uu 1 Buisnj 12M0d Buluuoou l DEET 33 34 Section 9 Parts Item SE Wi De P Sw1200 SW2000 P SW1200 SW2000 Sheet Metal Top PAS240 Rectifier Assembly PAE1050 PBE1050 26 02 Sheet Metal Left Side PAS242 PBS242 Single Phase Filter Network PAE800 PAS241 PBS241 AC Surge Network PAE802 SCR Harness PAH001 Single Sided Heatsink PAM2 Spring Pin Locator SPC12 37ZP Thermal Paste ETP PAM3 ESR75006PK PBM200 ED5004 PAM50 PAE1001 PAE1060 PAM4 ESR120002PK PAM202 WFN43 62 31 WSN25 62 50x42 39 PAE80 PAH016 PAS140A PAE2102 PAM1100 PAM1110 PAM1120 PAM1130 mall Module Blanking Plate PAS120A PAE2103 PAD241 PAC280 PAC281 PAC260 PAC261 AK111A PAC221 PAC201 PAS225 PAS230 PAK125 PAD125 PAH013 PAh012 PAH011 PAH010 PAK102A PAK101A WFN43 62 25 WSN25 62 50x42 39 PAM250 PAM251 BE501 BE500 BE600 PAE902 Schematic Decal 04 05 28 29 07 Front Sheet Metal Reinforcement Bracket Weld SCR Pa S amp HI Slo ojo o V A N ectifier Buss Bar teering SCR Assembly Steering SCR Heatsink Steering SCR Steering SCR C Isolation Flat Washer Voltage Jumper Decal Jumper Wire T1 Jumper Wire T2 Jumper Wire T3 Delta Jumper Wire T1 T3 Rectifier Bracket Right Side Rectifier Bracket Left Side Isolation Flat Washer N v in a Bi a a o N Ko Lm w N w Isolation Shoulder Washer Common Side Jump
38. ing You can always reach this screen except when entering or changing a password by depressing the home button on the front panel If the welder is left in some other screen the unit will automatically return to the home screen after a short time 10 Section 3 Normal feJ Eio POWER UP Press to the right or towards the 1 and momentarily hold the power switch located on the lower left side of the control panel The power supply initiates a self test This test lasts approximately 5 seconds During this test routine none of the welders s functions including welding will operate This is normal The test will verify system MELT LEST au LE RAM and system ROM At the end of the test it will display OK if all functions check out If the system has a malfunction the display will show a failure and the system will not operate During the self test all system LEDs will light so the operator can verify that the LEDs are working Note your screen may be slightly different When self test ends the display will automatically show the home screen the Normal Operate or Auto Weld screen depending in which mode the unit was left Any values in main current or main time are saved from the last time the welder was used Note values are ONLY saved after a weld is made or the home button is pressed Rotary Knobs The rotary knobs have an acceleration feature built into them As you turn the knobs faster the values change by greater a
39. ion and can injure skin and eyes Hot metal can cause burns Training in the proper use of the processes and equipment is essential to prevent accidents Therefore 1 Always wear safety glasses with side shields in any work area even if welding helmets face shields and goggles are also required 2 Usea face shield fitted with the correct filter Cover sparks and rays of the arc when operating or observing operations Wam bystanders not to watch the arc and not to expose themselves to the rays of the electric arc or hot metal 3 Wear flameproof gauntlet type gloves heavy long sleeve shirt cuffless trousers high topped shoes and a welding helmet or cap for hair protection to protect against arc rays and hot sparks or hot metal A flameproof apron may also be desirable as protection against radiated heat and sparks 4 Hotsparks or metal can lodge in rolled up sleeves trousers cuffs or pockets Sleeves and collars should be kept buttoned and open pockets eliminated from the front of clothing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partitions or curtains 6 Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can fly far Bystanders should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat from flames and arcs can start fires Hot slag or sparks can also cause fires and explosions Therefore 1 Remove all combustible materials
40. isplay the screens in English Spanish or French The upper rotary knob selects which language to use on the screens Once a language is selected all menus will be displayed in that language If the last row of the Maintenance Screen displays the H lock symbol the feature can not be reset with out entering the unlocking code See Code Section for detail on entering the code AUTOMATIC SAFETY SHUTDOWN This welder includes an Automatic Safety Shutdown There are two ways the safety shutdown can be activated Thermal Overload Protection This feature will shut the unit down in the event that the fan can not cool the power supply adequately The unit will not power up until it has returned to a safe operating temperature The unit can go into thermal overload for two reasons The first reason would be a malfunction in the unit itself The second reason would be that the duty cycle has been exceeded When the unit cools down the thermal overload protection will automatically reset After the thermal overload has reset the unit will function normally Shorted Weld SCR If the microprocessor detects voltage at the output terminals when the unit is not welding it will shut the unit off This means that one of the six main switching devices has shorted If this condition occurs the unit could potentially weld without triggering a gun This is a potentially dangerous condition The microprocessor detects this condition and shuts the welder down The
41. l appear Once you have selected the gun and set up the weld schedules as you like these settings can be saved in a Memory Preset location To save a schedule in a Memory Preset press and hold the desired memory preset button until the LED flashes you can release the button once it starts flashing This puts you into the review mode see previous section If the last row of the Programming Screen displays the H lock symbol the weld schedule can not be saved with out entering the unlocking code See Code Section for detail on entering the code Pressing the same Memory Preset button again stores the data in that Memory Preset location You are returned to the home screen after a few seconds Programmed 19 Optional Features GAS MODULE This module allows the use of shielding gas during welding To access the gas functions press the control button on the gas module This brings up the gas menu on the display This screen allows you to select the gas mode The upper rotary knob turns the gas mode on and off Note it is a good idea to use the shielding gas recommended by the stud manufacturer Off Mode This disables all gas functions for the selected gun On Mode This mode controls the gas flow during the weld cycle When the trigger is pulled the unit starts a pre flow gas cycle to purge the weld zone Gas continues to flow during the weld cycle After the weld is complete gas continues to flow while the molten metal cools
42. l be martensitic This structure will be quite sensitive to underbead cracking and it will have insufficient ductility to carry impact loads Therefore for maxi mum toughness in these steels a preheat of 700 F 370 C is recommended Consideration of the application and end use of the stud will further influence the welding procedures to be followed Stainless Steel Most classes of stainless steel may be stud welded The exceptions are the free machining grades However only the austenitic stainless steels 300 grades are recommended for general application The other types are subject to air hardening and they tend to be brittle in the weld area unless annealed after welding The weldable stainless steel grades include American Iron and Steel Institute AISI Types 302 304 305 308 309 310 316 321 347 410 and 430 Types 302 304 and 316 are most commonly used for stud welding Stainless steel studs may be welded to stainless steel or to mild steel as the application may require The welding setup used is the same as that recommended for low carbon steel except for an increase of approximately 10 percent in power requirement Where stainless steel studs are to be welded to mild steel it is essential that the 26 Section 5 Special Welding carbon content of the base metal not exceed 0 20 percent When welding stainless steel studs to mild steel with 0 20 to 0 28 percent carbon or to low carbon hardenable steels Type 308 309 o
43. matic mode this feature does not apply errors will always be reported If this feature is on all current under amp over errors errors 5 13 14 amp 15 See Trouble Shooting pages will be reported in the display For example if a current of 250 amps is selected and 280 amps is delivered this would trigger the 10 over current error The display would lock up and the reset button would need to be pressed to clear that weld output If the reporting feature is off then this example would not have generated an error and the operator would be able to continue without interruption The errors are calculated in the following manner If the set time is greater than 0 150 seconds then the error reporting limits are 10 If the set time is less than or equal to 0 150 seconds then the error reporting limits are 25 When using short weld times less than or equal to 0 150 seconds the mechanical time variations of gun lift become more significant relative to the weld time This can cause wide variations in delivered weld current As times shorten more less than or equal to 0 90 seconds control may not be able to stay within 25 all of the time Error reporting may cause unnecessary interuption to the operators work flow Therefore error reporting may be turned off SET USER CODE UNLOCKING FEATURES Starting at the home screen press the W scroll down button 7 times to met Med User Lote reach the set user code menu This menu is always locked
44. mer mode is off and the system does not detect ground i e the gun is air triggered the gun will cycle once without welding This is useful for checking lift settings in the gun If gas flow is enabled gas will flow during lift check This can be used on power up to purge the gas line 14 Section 3 Normal fej AE lives FEATURE LOCKING This function allows restricted access to none some or all of the power Feature locking supply s advanced features This is beneficial for many circumstances ALL Locked H For companies trying to establish an ISO9000 style program this prevents unauthorized changes to the set up If 0 5 seconds of gas pre flow time is programmed the unit can prevent operator adjustments to that time value Prevents changes to advanced features like pilot arc which should only be changed by experienced operators Prevents conflicts between shifts If a Memory Preset has been programmed by a 1st shift operator the Memory Preset may be over written by a 2nd shift operator If the Memory Preset feature is locked then this conflict is prevented and can be controlled by a supervisor From the home screen press the scroll down button 5 times to access the Feature Locking screen Note The Feature Locking Screen is always locked even if the user code has been entered in another screen To access this menu the user must unlock it with the user code Once unlocked the upper rotary knob selects one of 3
45. mounts When you turn the knobs slower the values change by small amounts For example you would like to set the welder to 1000 amps but the display is showing 50 amps By turning the the knob quickly the display will jump in large steps towards 1000 amps As the display value gets close to 1000 amps turn the knob slowly to dial the exact value WELD SETTINGS Recommended Power Supply Current amp Time Settings The top rotary knob adjusts the data on the second line on the screen In the Normal Operate screen the knob would adjust the main weld current Clockwise rotation increases weld current and counter clockwise rotation decreases weld current The bottom Rotary Knob adjusts the main weld time Like the current turning the knob clockwise increases the main weld time Stud Size Current Time Stud Size Current Time 1 4 350 A 250 sec 6mm 350 A 250 sec 5 16 420 A 310 sec 8mm 420 A 310 sec 3 8 530 A 380 sec 10 mm 580 A 430 sec 1 2 800 A 500 sec 12 mm 720 A 500 sec 5 8 1000 A 680 sec 14mm 880 A 590 sec 3 4 1325 A 750 sec 16 mm 1040 A 660 sec 7 8 1680 A 830 sec 20 mm 1440 A 780 sec 1 2000 A 870 sec 24 mm 1900 A 850 sec Stud Gun Settings The time amp current setting in the previous section will vary with the stud gun s lift and plunge settings Typical values are 3 32 for gun lift and 1 8 for gun plunge For this power supply stud lift is recommended to be at 3 32 11 Normal Operation WELDING There
46. n the preheating or postheating operation may be eliminated if the parts are handled in a manner that prevents damage to the studs Low Alloy Steel Generally the high strength low alloy steels are satisfactorily stud welded when their carbon content is 0 15 percent or lower This range fits the analyses of low alloy steels used in welding and forming operations If the carbon content exceeds 0 15 percent it may be necessary to preheat the work to a low preheat temperature to obtain desired toughness in the weld area When the hardness of the heat affected zones and the stud fillet does not exceed 30 Rockwell C studs can be expected to perform well under almost any type of severe service Although good results have been obtained with hardness ranges up to 35 Rockwell C it is best to avoid extremely high working stresses and fatigue loading In special cases where microstructures are important the weld should be evaluated and qualified for the specific application considered Since alloy steels vary in toughness and ductility at high hardness levels weld hardness should not be used as the sole criterion for weld evaluation Heat Treated Structural Steel Many structural steels used in shipbuilding and in other construction are heat treated at the mill Heat treated steels require that attention be given to the metallurgical characteristics of the heat affected zone Some of these steels are sufficiently hardenable that the heat affected zones wil
47. nickel copper and nickel chromium iron alloy stud welds tend to contain porosity and crevices The mechanical strengths however are usually high enough to meet most requirements The weld itself should not be exposed to corrosive media 28 Section 6 ayedad 40 ul Jlun pu s sant AH4 A BULIM 1499912 UE ASA uno pms isnipy zg ue lo aedad 40 ul Jlun pu s sant AOA SulAA eDd14 D9 9 UE KHA uno pis 3snlpy ue o EE OF WILL S Suna s YI AOA und pris isnipy uea sant AOA BULUIM eDd14 D9 9 UE JH A uone2i dde u Al8 ay 104 1431 ool aq Aew SU DdS Os V sBulJas UNS prys jeayeW gt PeyD pepeeoxa aq Aew sanjea asauy Udy 43N Ue SHUI dS pue jua U0D uoque2 a peayew aseq JO pnjs U 8ueu2 JULIYIUBIS E SEM 4 U J s8ulqjas un d pue yl uns A syuiod 18312 DdS 24 UIYIIM SEL JUIN Jas EYI ua uoneodde uaals au 104 34317 00 aq ew SU dS ole s8un s un8 prys lelu Jeuu 294D p p ox aq Aew sanjea gea Uu Un BU SHUI Dds pue jUa UOD uoque2 a peayew aseq JO PNIS ul 8ueu2 JURDYIUBIS E SEM 4 U J ssulyjas asunjd pue y un Alda syulod 18348 DdS 24 UIYIIM SEL JUBIND Jas YZ Aua uopg2udde u Al8 ay 104 34317 00 aq Aew SU DdS Os V sBuljjJas UNS prys Jenoyew 3294 p p 5x aq ew sanje asayy u u 43N DUB SHI dS pue jUa U0D uoque2 a peayew aseq JO pnjs u 8ueu2 JURDYIUBIS E SEM 4 U J ssulyjas asunjd pue y
48. o the control transformer terminals H1 and H4 These wires must remain attached after configuring the control transformer jumper links 230 Volt Configuration 460 Volt Configuration Wi E Bi For the 460V configuration the extra jumper link may be secured to the 10 24 stud located on the base pan in front of the 12 position barrier strip PH E E E Connecting Incoming Power To connect incoming electrical power it is necessary to remove the right side cover Remove the screws retaining the right side panel Use a 3 8 nut runner A WARNING socket or a large flat blade screw driver Strip back the outer cable jacketing so there is approximately 4 of insulated leads Strip approximately 1 2 of insulation on each conductor Crimp a lug with a 1 4 hole onto the green conductor Thread the 4 leads through the cord grip on the lower left hand side of the back of the welder Connect the red white and black wires to L1 L2 and L3 on the contactor Use a large flat bladed screwdriver to secure the incoming leads to the contactor These connections should be tight Tighten cord grip onto incoming cable jacket Connect the ground lead to the long bolt on the floor pan as shown in the diagram on the right There is already a green with yellow stripe wire attached to this bolt Trap this lug between the two nuts and tighten the nuts Normal Operation Controls
49. put BAUD rate If the Prinker Speed lower left corner of the Printer Speed screen displays the H lock symbol DOE Dale then the Printer Speed can not be changed without entering the unlocking code See Code Section for details on entering the code Pressing W G Foe Hore scroll down again returns the display to the Limit Current screen BAUD RATE 9600 4800 2400 1200 Data Bits 8 Stop Bits 1 Parity None 22 Section 4 Optional MULTI GUN The Multi gun feature allows the welder to support 2 to 4 total stud Hormel Orerate GUM welding guns All switching is transparent to the operator An operator fair Currert can grab any of the multiple guns and weld with that gun s weld parameters He can then set that gun down and pick up another gun and weld with THAT gun s parameters All parameter switching is handled by the microprocessor In fact the unit can be treated as being 4 separate welders All parameters including parameters in optional modules can be set independently of one another The only restrictions are that only 1 gun can weld at a time and the duty cycle of the welder can not be exceeded To change weld parameters for a given gun press the control button for that gun Note if you only have 2 guns installed and press the control button for gun 3 or gun 4 nothing will happen For instance to set the weld parameters for gun 2 press the gun 2 control button The Gun indicator in the upper right will change to show GU
50. r 310 studs are recommended Because of the composition of the weld metal when chromium nickel alloy studs are welded to mild steel the weld zone may be quite hard The hardness will depend on the carbon content in the base metal It is possible to overcome this by using studs with high alloy content such as Type 309 or 310 It is also suggested when welding stainless steel studs to mild steel that a fully annealed stainless steel stud be used Plated Material Stud Welding can be successfully accomplished onto plated base materials Care must be taken when arc welding onto plated materials as harmful gasses can be generated Typical plating on base materials is zinc on galvanized sheet The rust prohibitive zinc is burned away in the weld zone and no longer provides rust protection at the weld zone Even if stainless steel fasteners are used there is potential for corrosion in the weld zone Frequently corrosion resistance is desired on the fastener yet the cost of stainless is prohibitive Many manufac turers produce weld studs with various platings Most common is a nickel plate but other platings are available As with plated base materials the plating is burned away in the weld zone There is a potential for corrosion in the weld zone Shielding Gas Selection for Steels The choice of gas depends on two factors weld penetration and appearance Pure argon provides the best look ing welds but has the least weld penetration To increase penetr
51. re injury or death DO NOT use welding e current in damp areas if movement is confined or if there is danger of falling 1 Be sure the power source frame chassis is connected to the ground system of the input power 2 Connect the work piece to a good electrical ground 3 Connect the work cable to the work piece A poor or missing connection can expose you or others to a fatal shock 4 Use well maintained equipment Replace worn or damaged cables 5 Keep everything dry including clothing work area cables torch electrode holder and power source 6 Make sure thatall parts of your body are insulated from work and from the ground 7 Donotstand directly on metal or the earth while working in tight quarters or a damp area stand on dry boards or an insulating platform and wear rubber soled shoes 8 Puton dry hole free gloves before turning on the power 9 Referto ANSI ASC Standard Z49 1 listed on page 6 for specific grounding recommendations Do not mistake the work lead for a ground cable ELECTRIC AND MAGNETIC FIELDS Electric and magnetic fields may be dangerous Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding and cutting current creates EMF around welding cables and welding machines Therefore 1 Welders having pacemakers should consult their physician before welding EMF may interfere with some pacemakers 2 Exposure to EMF may have other health eff
52. to the program stored in that location Use a felt tipped pen to make your notes Do not use pencil or ball point pen because these will damage the write on surface The felt tip markings can be removed with a damp cloth Recalling Stored Settings To recall a weld schedule press the button next to the setting you want to recall In multi gun systems be sure that the gun is correctly selected for the settings you wish to recall The display will change to show the recalled values as well as showing which program number you are using Additionally the LED next to the program you selected will light up You are ready to weld with these settings Press amp hold the button next to the memory location you wish to review 7 Fa GURL The LED next to that location will start to flash and the display will change Preset Butto to the review screen Once the LED flashes you may release the button Hgain to Program f Pressing the scroll down button allows you to see all of the stored parameters for that weld schedule No values may be changed This Ss KEULEN mode is for reviewing data only To exit the review press the amp Home key on the front panel 18 Section 4 Optional F Fil Pilot Tire H sto Pore Harmer Status OFF HS For Pere Current Upper Current Lower H Ss poe Die MASAN Pressing the scroll down button moves to each successive screen The large arrows show the order that the screens wil
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55. unit can be restarted but will shut down almost immediately once this condition is detected The unit must be repaired 17 Optional Features GENERAL INFORMATION The system microprocessor automatically detects and identifies each installed module Once detected the system is ready to use the optional feature All optional features are accessed by pressing the control button s on the optional feature When working on a multigun unit all setting changes are made to the active gun To make a gun the active gun press the gun control button for that gun or air trigger the gun you wish to adjust i e if you want to recall review change settings for Gun 3 press the gun 3 button on the gun control panel or pull the trigger on Gun 3 while gun 3 is in the air When a unit is set up for multiple guns it keeps separate settings for each gun Only settings for the active gun can be changed PRESET MEMORY MODULE This module stores 8 different weld schedules for EACH GUN This module stores all the weld parameters for a given setting These parameters include Main arc time Main arc current Pilot arc time Pilot arc current Hammer Mode The module also stores settings for option features Gas Mode Gas Pre Flow Time Gas Post Flow Time Upper Time Control Limit Lower Time Control Limit Upper Current Control Limit Lower Current Control Limit The Preset Memory module has a write on surface next to each decal to jot down a reminder as
56. uu aU o OD ayedau souinbas pue Suliuonounj euu s paeoq ay Udy Sunmlllq Jo Jo J UO s paeoq I luo p jre4 Se HES ay JO Pp ui ayy Je u GFT aus ayy yey HIA 4equINN uon3V Al3294409 s sneO jq ssod Su uce l 40449 Suljeay JAO Section 6 31 System Maintenance SYSTEM MAINTENANCE This system has been designed to be essentially maintenance free The only recommended maintenance is to blow out the power supply once a year Dirt grinding dust and other contaminates can accumulate over time and they deteriorate the power supply s cooling performance If the unit is located in a dirty environment the unit should be blown out more frequently Typically most trouble stems from the stud gun The stud gun should be serviced once every quarter Monthly service may be required if use is exceptionally heavy Please refer to the stud gun service manual for maintenance guidelines and instructions 32
57. well away from the work area or cover the materials with a protective nonflammable covering Combustible materials include wood cloth sawdust liquid and gas fuels solvents paints and coatings paper etc 2 Hotsparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below Make certain that such openings are protected from hot sparks and metal 3 Do not weld cut or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Have appropriate fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained for proper use 5 Donotuse equipment beyond its ratings For example overloaded welding cable can overheat and create a fire hazard 6 After completing operations inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire Use fire watchers when necessary 7 For additional information refer to NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Processes available from the National F ire Protection Association Batterymarch P ark Quincy MA 02269 ELECTRICAL SHOCK Contact with live electrical parts and ground can cause seve
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