UA500 Arc Stud Welder Manual
Contents
1. UA500 Solid State Arc Stud Welding System UA 500 Arc Stud Welding System Owner s Manual e Installation e Operation e Maintenance MIDWEST FASTENERS INC 450 Richard Street Miamisburg OH 45342 Phone 800 852 8352 Fax 937 866 4174 2010 Midwest Fasteners Inc All rights reserved Printed in U S A TABLE OF CONTENTS GENERAL Were 2 INTRODUCTION What is ARC Stud Welding n 5 SETUP 8 OPERATION Supplying Power Connections and Startup Control Settings Weld G n Setup ei initial al First Le fn canili asia Weld joint QUALITY Lidia iia MAINTENANCE Preventive Maimtenanee 14 reel le EE 14 PARTS SPECIFICATIONS UA500 Welder Specifications 16 Weld Gun Specifications i 17 UA500 Welder Exploded View amp Parts List 18 Weld Gun Exploded View amp Parts List 20 UA500 Electrical Schematpe eee en 2 Ie TTT 23 FOREWORD Your new stud welding equipment is carefully constructed of the finest components and materials available Used properly this equipment will give you years of profitable efficient Service The system incorporates the latest in engineering advances for completely reliable welding of mild steel stainless steel The assembled unit is completely performance checked The welder is delivered to you in functional electromechanical condition A careful study o WARRAN2. SPECIFICATIONS Power Requirement 208 230 VAC 60 Hz 100 Amp or 460 VAC 60 Hz 50 Amp Pin Stud Range 10 GA 1 2 dia Weldable Materials Mild Steel Stainless amp Aluminum Weld Rate 14 minute max for 1 4 dia studs 5 minute max for 1 2 dia studs Dependent on stud size Weld Voltage 900 Amps at 40 VDC Cables urna ia 25 Ground Cable with C Clamp 50 Combo Cable Set 2010 MIDWEST FASTENERS INC UA500 Stud Welding System UA500 ARG STUD WELDING GUN SPECIFICATIONS Weight anice 4 5 pounds not including cables Stud Range 10 GA 1 2 dia Weldable Materials Mild Steel Stainless amp Aluminum Material High strength impact resistant poly carbonate Cable Length 4 17 2010 MIDWEST FASTENERS INC UA500 Stud Welding System UA500 EXPLODED VIEW e k 18 2010 MIDWEST FASTENERS INC UA500 Stud Welding System UA500 PARTS LIST DIN ELA LA 1 2 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 1 Part No 050 3001 54 050 3001 53 050 3002 33 050 1001 62 050 3002 32 050 3001 04 050 3001 88 050 3002 38 050 3002 36 050 3002 45 050 3002 35 050 3002 34 060 3068 00 060 3115 00 060 3068 00 050 3001 12 050 1002 87 050 1004 78 050 3001 11 050 300
3. and use lockout tags Significant DC voltage can still exist in this eguipment after removal or shut down of the input power Turn off all eguipment when not in use ELECTRICAL SHOCK HAZARD Contact with live electrical parts and ground can cause severe injury or death DO NOT weld in damp areas or while eguipment or clothing are damp or wet Do not touch the stud if you are in contact with the work ground or another electrode from a different machine Don t stand directly on metal or the earth stand on dry boards insulating mats or an insulating platform Before turning on power be sure you are wearing appropriate protective clothing high topped heavy rubber soled shoes long gauntlet style dry flameproof hole free insulated gloves heavy long sleeve cuffless shirt heavy cuffless trousers and a welding helmet or cap GENERAL WELDING JOB SAFETY Use this eguipment only for its intended purpose Use well maintained eguipment Replace worn or damaged cables or parts immediately bare wiring can kill Do not drape cables over your body Keep all panels and covers securely in place Do not overload electrical wiring be sure power supply system is properly sized rated and protected to handle the unit Don t connect multiple guns or work cables to a single weld output terminal Follow rated duty cycle and allow overheated eguipment adeguate cooling periods Do not block or filter airflow to unit DO NOT weld
4. if movement is confined or if there is danger of falling Wear a safety harness if working above floor level Shut unit down and remove weld stud from the stud weld gun when not in use ELECTROMAGNETIC FIELDS AND RFI Electric and magnetic fields may be dangerous Welder operators having pacemakers should consult their physician before welding EMF may interfere with some pacemakers Exposure to EMF may have other health effects which are unknown Connect the work cable to the work piece as close as possible to the area being welded Keep welding power source and cables as far away from your body as possible Electromagnetic energy can interfere with sensitive electronic eguipment such as computers and computer driven eguipment such as robots FUMES HAZARDS Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health particularly in confined spaces Do not breath fumes and gases Always ventilate confined spaces or use approved air supplied respirator Don t weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area Don t weld near degreasing cleaning or spraying operations FIRE SAFETY AND BURN PREVENTION ARC RAYS CAN BURN EYES AND SKIN Always wear safety glasses with side shields in any work area Even if wearing a welding helmet face shields and goggles are also required Wear goggles over safety glasses when chipping wire brushing
5. or grinding slag Chipped slag may be hot and can fly far Bystanders should also wear goggles over safety glasses Use protective non flammable screens or barriers to protect others from flash and glare Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric arc or hot metal Welding on closed containers such as tanks drums or pipes can cause them to blow up Do not weld where flying sparks can strike flammable material Remove all combustible materials a minimum of 35 ft away from the welding arc or cover the materials with a protective nonflammable covering Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a 2010 MIDWEST FASTENERS INC UA500 Stud Welding System hidden smoldering fire or hres on the floor below Make certain that such openings are protected from hot sparks and metal Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Have appropriate fire extinguishing eguipment handy such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained for proper use 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 NOISE CAN DAMAGE HEARING Noise from some processes or eguipment can damage hearing Therefore wear approved ear protec
6. 1 87 Description Fuse 4 Amp Fuse 10 Amp Handle Decal Cover Cooling Fan Potentiometer Time Coil Choke Wheel Cotter Pin Wheel Axle Chassis Front Panel Camlok Receptacle Positive Control Receptacle Camlok Receptacle Negative Output Decal Control Knob Power Indicator Light Front Panel Decal Potentiometer Current 050 3002 40 050 3001 42 050 3001 80 050 3002 02 050 3002 44 050 3001 05 050 3001 65 050 3002 42 050 3002 43 050 3002 46 050 3002 16 050 3001 67 050 3002 11 050 3001 52 050 3001 66 050 3002 37 050 3001 78 050 3002 23 050 3002 22 050 3001 01 E E Fa N E K Fei Fi K HA CNN ra EA Fei rr 2010 MIDWEST FASTENERS INC UA500 Stud Welding System Description Circuit breaker Transformer Terminal Strip Weld SCR Weld Bridge Jump Bar Plastic Standoff Mounting Bracket Heat Sink Thermostat Weld Bridge Heat Sink Potentiometer Capacitor Commutation PC Board Mounting Bracket Resistor Fuse Holder Arc Rectifier Bracket SCR Support Arc Terminal Strip Support Arc PC Board PC Board Standoff Wiring Harness UA500 UA500 ARG STUD WELDING GUN EXPLODED VIEW 2010 MIDWEST FASTENERS INC UA500 Stud Welding System 20 UA500 ARG STUD WELDING GUN PARTS LIST 21 Ken ken do ke ke ke ke ke ke I IN Fa A y Part No 196 IM04 01 196 IM04 02 196 IM04 03 196 IM04 04 196 IM04 05 196 IM04 06 196 IM04 07 196 IM04 08 19
7. 6 IM04 09 196 IM04 10 196 IM04 11 196 IM04 12 196 IM04 13 196 IM04 14 196 IM04 15 196 IM04 16 196 IM04 17 196 IM04 18 196 IM04 19 196 IM04 20 196 IM04 21 196 IM04 22 Description Front Cover Jam Nut Chuck Adapter Dust Bellows Nylon Bushing Front Cover Cable Clamp Adapter Screw Plunge Dampener Soft OPT Plunge Dampener Med OPT Plunge Dampener Hard OPT Cable Clamp Adapter Internal Weld Cable Internal Weld Cable Lock Washer Internal Weld Cable Screw Lifting Rod Main Spring Lift Release Moveable Core Bearing Retainer Lift Bearing Lift Bearing Spring Moveable Core Shaft Shaft Retainer Shaft Spring Seat 2010 MIDWEST FASTENERS INC UA500 Stud Welding System EEE E EEE EE E E i i i i i i EA ke i EA bet Eet 196 IM04 23 196 IM04 24 196 IM04 25 196 IM04 26 196 IM04 27 196 IM04 28 196 IM04 29 196 IM04 30 196 IM04 31 196 IM04 32 196 IM04 33 196 IM04 34 196 IM04 35 196 IM04 36 196 IM04 37 196 IM04 38 196 IM04 39 196 IM04 40 196 IM04 42 196 IM04 41 196 IM04 43 196 IM04 49 Description Core Return Spring Gun Body Leg Set Screw Front Coil Yoke Gun Coil Rear Coil Yoke Rear Coil Yoke Set Screws Adjustable Core Rear Cap Rear Cap Screw Trigger Switch Ass y Weld Cable Anchor Plate Anchor Plate Screw Anchor Plate Kep Nut Handle Cover Handle Cover Upper Screw Handle Cover Lower Screw Weld Cable Strain Relief External Weld Cable Assy Male Weld C
8. By making sure that the gun and welder are set up properly you will have the best welding results 95 of all stud welding problems are due to improper gun set up or improper power settings Once you have set up as described previously the actual welding process is straight forward Begin your first test welds by 1 Place the stud to be welding into the weld chuck 2 Place a ferrule into the ferrule grip this step is not necessary if you are using a Spark shield 3 Position the end of the stud onto the location where you want it welded 4 Press the gun downward so the ferrule is sitting on the base metal 5 Pull the trigger to begin the weld seguence Hold the gun still during the arcing process 7 After the weld has completed continue to hold the gun still for 1 second to allow the molten metal to solidify a PLUNGE ADJUSTMENT Ba we E Da s a Tool metani TT well mp d Lotta Press tool towards wack until fermule is againd wark Position too against work 8 Remove the weld gun by lifting straight up off the welded stud Remove the ferrule by breaking 1t away 9 Inspect the test weld and make further adjustments to the controls and gun setups as necessary until satisfactory welds are being made consistently 12 WELD JOINT QUALITY Inspect the weld quality visually reference diagram below WELD QUALITY VISUAL REFERENCE GOOD WELD Weld fillet evenly distributed a
9. Controller OEUA 500 00 Weld Gun Combo 067 0011 00 I Cable Set ARES 100 50 N Za y S Ground CY A Cable ARGC 100 25 The stud welding process is as follows The stud is placed in the collet of the Weld Gun and then positioned against the workpiece The weld gun trigger is depressed and through operation of the stud welding controller and the design of the stud an arc is drawn which melts the base of the stud and a proportionate area of the workpiece The stud is then forced or plunged by the weld gun into the molten pool and held in place until the metals resolidify This high quality fusion weld is completed in milliseconds The ARC stud welding process produces weld power through one of three standard DC welding power sources These are Transformer Rectifier type Motor Generator type or Storage Battery type A ceramic ferrule is required in ARC stud welding to maintain the proper atmosphere in the weld area ARC stud welding is generally used for studs over 1 4 in diameter or where heavier base metals are involved ARC STUD WELDING PROCESS 1 Studis placed against workpiece and weld gun trigger depressed 2 Stud is lifted by weld gun and initiating arc is drawn 3 4 Weld solidifies and ferrule is removed H 2010 MIDWEST FASTENERS INC UA500 Stud Welding System SETTING UP THE WELDER SUPPLYING POWER LOCATING THE POWER SUPPLY T
10. ROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 1 Gun lifts but stud does A Support arc fuse s blown Test and replace if defective not weld B Loose or broken wiring on Check wiring and secure if support Arc module or main necessary rectifier C Defective PC board Test and repair or replace D Improper gun lift adjustment Readjust gun lift Power supply buzzes A Jumper links on main transformer Re link jumpers properly for incoming loudly or blows main connected improperly voltage see decal inside rear door fuses when powered on B Shorted SCR on main rectifier Test and replace if defective C Defective main transformer Test and replace if defective Circuit breaker trips A Unit is overheated Make sure fan is operating Allow when welding or unit to cool Reduce weld rate triggering gun B Excessive gun free air triggering Avoid repeated gun free air triggering Circuit breaker trips A Defective thermostat in main Test and replace if defective transformer or main rectifier B Defective main rectifier Test and replace if defective C Gun not lifting Check gun setup and gun lift and readjust as reguired Unit does not operate A Blown incoming line fuses Test and replace if defective at all B Jumper links on main transformer Re link jumpers properly for incoming connected improperly voltage see decal inside rear door 15 2010 MIDWEST FASTENERS INC UA500 Stud Welding System UA500
11. TY All parts used in the assembly of your MIDWEST FASTENERS UA500 Arc Welding System are fully guaranteed for ninety 90 days from factory shipment date Under this warranty MIDWEST FASTENERS reserves the right to repair or replace at its option defects in material or workmanship which occur during the warranty period Notice of any claim for warranty repair must be furnished to MIDWEST FASTENERS within ten 10 days after the defect is discovered MIDWEST FASTENERS does not assume liability for shipping or liability for any labor or material related to use of this system unless such costs are expressly authorized in writing by MIDWEST FASTENERS MIDWEST FASTENERS I or use not in accordance to the operating instructions furnished by the manufacturer or for reasons beyond its control The manufacturer does not assume any liab This warranty is valid only when welding with welding studs purchased from or approved by MIDWEST FASTENERS 2 2010 MIDWEST FASTENERS INC UA500 Stud Welding System WELDING SAFETY PRECAUTIONS AND WARNINGS INSTALLATION AND SERVICING SAFETY Improperly installed or improperly grounded eguipment is a hazard Always have gualified personnel perform the installation trouble shooting and maintenance Do not perform any electrical work unless you are gualified to do the work Be sure the system is properly grounded Maintain this unit according to the manual Disconnect input power before servicing this eguipment
12. able Connector Control Cable Strain Relief Control Cable Assy UA500 ELECTRICAL SCHEMATIC ECH 210 128 ZU 198 R YOM mo vcd 2010 MIDWEST FASTENERS INC UA500 Stud Welding System yaya NYI SION EU 22 NOTES 23 2010 MIDWEST FASTENERS INC UA500 Stud Welding System 24 2010 MIDWEST FASTENERS INC UA500 Stud Welding System 450 Richard Street e Miamisburg OH 45342 www midwestfasteners com Fax 937 866 4174 800 852 8352 04 10
13. asher and nut A bend lest can be used on threaded studs as well In an acceptable weld failure will occur in the stud material or tear out of a thin base plate Failure in the weld reguires adjustment of procedure and or settings Weldable Material Combinations Base Material Stud Materials Mild steel 1006 1022 Mild Steel 1010 1020 Stainless Steel series 300 except 303 Stainless Steel Mild Steel 1010 1020 series 300 except 303 Stainless Steel series 300 405 410 and 430 except 303 Aluminum series 5000 Aluminum 5356 13 2010 MIDWEST FASTENERS INC UA500 Stud Welding System PREVENTIVE MAINTENANCE Your MIDWEST FASTENERS welder is designed for long service with minimal care Ordinary common sense maintenance will keep it operating efficiently The following are a few tips on preventive maintenance 1 Treat the cables with respect Avoid sharp bends or kinks which may break the cables DO NOT use the cables as a towline to drag or lift the controller Avoid damaging or straining the cables where they enter the gun or controller Louvers on the sides of the controller should be free from obstructions at all times to prevent overheating Keep the controller and gun clean and dry free of grease water dust and dirt Do not lubricate any part of your weld gun The weld gun is for welding studs only Do not use the weld gun as a multipurpose tool 1 e Hammer banging studs to test welds or br
14. bo cable between gun and power control unit it must be uncoiled 4 Set up the gun in accordance with instructions starting on page 9 of this manual ARC WELDING SETUP CONNECTIONS Power Supply Controller Ground Cable with clamp un Adjust the weld timer and amperage to the approximate settings shown on the face of unit a Turn circuit breaker on 7 Insert a stud in the chuck and a ferrule in the ferrule grip 00 Hold the gun perpendicular to workpiece and depress gun until ferrule is firmly sealed against work surface 9 Press trigger to initiate weld Do not press trigger again 10 Do not move gun during weld cycle After weld cycle is completed wait a moment to allow molten metal to solidify then remove gun from stud 11 Inspect weld results and adjust setup as required NOTE All cables must be uncoiled when in use m Disconnect switch By Customer 2010 MIDWEST FASTENERS INC UA500 Stud Welding System SETTING UP THE WELDER CONTROL SETTINGS The control settings establish the weld cycle parameters Understanding the effect of each control will aid in guick and efficient setup for the first weld ON OFF Power Switch When the circuit breaker located on the front of the unit is turned ON the unit is energized and the pilot light will light The circuit breaker provides protection to the components in the unit Should an overload occur the circu
15. e flux load PLUNGE ADJUSTMENT Loosen set cree Ione esch side af guri to adjust the leg ard feat assembly In ane aut of the dun JES I tr T D A SES Depth ko Note These are instructions for standard ferrules For reduced fillet ferrules only recommended for very specific applications decrease the amount of plunge by half 2010 MIDWEST FASTENERS INC UA500 Stud Welding System Plunge Settings For Arc or Gas Arc Stud Welding For Short Arc or Gas Short Arc the stud should protrude past the end of the spark shield by about 0 04 or Imm This is about the same as the flange thickness on flanged style studs For standard time duration Gas Arc the plunge should be set at about 2 flange thicknesses or 2mm ADJUSTING GUN LIFT The lift controls the arc length and thus is one factor in controlling the heat of the welding process Lift should be set as shown below depending on the diameter of the stud to be welded Single phase eguipment 1 8 lift for most applications Three phase eguipment 1 16 lift for studs up to 5 16 diameter 3 32 lift for studs 5 16 to 1 2 diameter 1 8 lift for studs over 1 2 diameter Measuring Lift It is straight forward to measure lift For safety from accidental activation always disconnect the weld cable from the power supply before making any gun adjustments or performing any service on the gun To measure gun lift hold a scale against some fixed part of the tool The f
16. eak ferrules Scraper removing rust scale or weld splatter etc We recommend that the transformer and recti fier be cleaned occasionally by blowing out with low velocity stream of compressed air so that maximum cooling will be accomplished This should be done periodically depending upon the location of the unit and the amount of dust and dirt in the atmosphere The case cover should be removed and a clean dry air stream should be used for this operation TROUBLESHOOTING When troubleshooting the UA500 the following precautions must be observed 1 Power must be TURNED OFF HIGH VOLTAGE NOTE Dangerous voltage levels can still be present in the controller even after power is disconnected Before attempting any inspection or work on the inside of the unit open the branch circuit or main disconnect switch or remove the circuit fuses Turning off the unit does not remove voltage from the power terminals inside the unit This can only be done by opening the primary circuit The use of a volt ohmmeter is recommended to verify where any voltage may or may not be present The use of a continuity tester or trouble shooting light can be used for continuity checking disconnected cables only The troubleshooting chart on the following page can assist in locating and fixing problems with the UA500 Continues gt 2010 MIDWEST FASTENERS INC UA500 Stud Welding System TROUBLESHOOTING CHART P
17. ed when welding headed anchors and shear connectors The standard gun ships with a small foot and 9 legs The heavy duty gun ships with a medium foot and 14 legs FOOT amp LEG COMPONENTS Foie a up Leg tal Le wl p D Fool Leg Wieda The foot is installed on the ends of the legs Unscrew the flat head screws from the ends of the legs Place the trim washers on the flat head screws and place the screws through the adjustment slots in the foot Reattach the screws to the legs BS e Lgs ineert into man Body Leg Holes Moe mac Uc Masone the gs foco he nfe cul gp body a they bre up vih thee Let zi sews 2010 MIDWEST FASTENERS INC UA500 Stud Welding System Insert the legs into the gun body leg retainers Line up the flat on the leg with the set screw The set screw will bite into the flat region and hold the leg securely Tighten the set screws in the side of the legs If the set screw bites into the round portion of the leg it will damage the leg so it doesn t inset into the gun body leg retainer any more FERRULE GRIP SPARK SHIELD REMOVAL amp INSTALLATION There are three set screws two on a gas foot that retain the ferrule grip or spark shield in the foot Loosen all three set screws Push the grip or spark shield into the foot The grip is sometimes a tight fit so press it firmly into the foot so it seats against the back stop The two side holes in the ferrule grip should line up with
18. he proper location of the power supply is essential for dependable service The unit should be located so as to allow for free air movement into and out of the power supply Consideration should be given to allow the least exposure possible to dust dirt moisture and corrosive vapors A minimum of 18 inches of unrestricted space must be maintained between the power supply s front and rear panels and the nearest obstruction The underside of the power supply must be completely free of all obstructions Attention should be given to ease of removal of the power supply s enclosure for maintenance functions ELECTRICAL INPUT REOUIREMENTS This welding power supply is designed to be operated from single phase 60hz AC Incoming power lines which have a voltage rating that corresponds to one of the input voltages shown on the nameplate and a solid earth ground Consult your local electric utility if there is any guestion about the type of electrical system available at the INPUT VOLTAGE SETTINGS installation site or how proper connections to the welding power supply are to be made CHANGING THE INPUT VOLTAGE If Reguired The power supply is shipped setup for 460 volts The input voltage jumper links provided on the primary terminal board permit the unit to be operated from various line voltages and freguencies 208 230 460 volts at 60 hertz If the power supply is to be operated at some voltage other than 460 volts the input vo
19. it breaker will trip This in turn shuts the unit off The circuit breaker is a manual reset type therefore if it should trip it must be reset FUI is a 4 amp delay type fuse which protects the control circuit FU2 and FU3 are 10 amp delay type fuses which protect the sustaining arc circuit WELDER CONTROLS APPROXIMATE SETTINGS STUD TIME CURRENT INCHES SEC 1 4 25 40 5 16 30 45 3 8 33 60 1 2 55 85 Current Weld current adjustment may be made by means of the current control on the front panel adjustable from 100 amps to 900 amps Time The weld timer on the front panel regulates the duration of the weld current Polarity Selection Cables On straight polarity which is normally used the ground is positive To reverse polarity simply reverse the weld ground cables on the front of the unit The welders controls should be set initially as shown on the Approximate Settings chart on the front panel sample diagram below in accordance with the diameter of arc stud being welded UA 500 ULTRA ARC ON CURRENT ASTENERS ING 2010 MIDWEST FASTENERS INC UA500 Stud Welding System SETTING UP THE WELDER WELD GUN SETUP Following the previous instructions the weld gun should now be properly connected to the welding system The weld gun needs to be properly set up and adjusted for the stud to be welded A different and correctly sized chuck and fe
20. ltage jumper links must be changed See the input voltage label inside the unit s back door reference diagram below for the various arrangements of the jumper links for the specific input voltage NOTE If only one jumper link is reguired on each grouped terminals it is recommended that the unused jumper links be placed across the terminals which are to be used This will prevent losing the jumper links which are not reguired for this connection POWER CONTROL UNIT TRANSFORMER RECTIFIER 208 230 460 VOLT e 60HZ e SINGLE PHASE 208 230 VOLT OPERATION 100 AMP FUSETRON FUSES OR CIRCUIT BREAKER 460 VOLT OPERATION 50 AMP FUSETRON FUSES OR CIRCUIT BREAKER TRANSFORMER TERMINAL BOARD JUMPER BAR INSTALLATION 208 VOLT 12 Gi I 30 40 o AD 7 o 6 1 2010 MIDWEST FASTENERS INC UA500 Stud Welding System SETTING UP THE WELDER COMPONENT CONNECTIONS AND STARTUP Ground Cable connect the male end to the receptacle marked POSITIVE on the power control unit and securely fasten the C clamp to the workpiece Welding Cable connect the male end to the receptacle marked NEGATIVE on the power control unit and the female end to the male connector on the gun weld cable Control Cable connect the male end to the receptacle marked CONTROL on the power control unit and the female end to the male connector on the gun control cable NOTE When using 50 ft Com
21. ront cover or the foot will work well Press the trigger so the tool activates the lift mechanism Now measure again The lift is the difference between the two measurements MEASURING LIFT Adjusting Lift To adjust lift remove the slotted screw holding the rear cap in place Put the rear cap aside Loosen the nylon tipped set screw that holds the adjustable core in place To increase lift turn the adjustable core screw counter clockwise To decrease lift turn the adjustable core Screw clockwise Each half turn is 025 ARC STUD WELDING PROCESS Lown sen Cos et re LK OY CZ H a SAUNA After properly setting the lift retighten the nylon tipped set screw to keep the adjustable core in place Replace the rear cap and tighten the rear cap screw It is important that the rear cap is in place as the prevents dirt and other contaminants from entering the gun and fouling the lift mechanism WELD GUN FUNCTIONS The weld gun automates the stud welding process It performs several key function 1 It holds the stud 2 It holds the ferrule spark shield or gas delivery system 3 It strikes the arc 4 Establishes the arc length lift distance 5 Via the power supply the gun controls the arc time 6 Controls the rate of plunge of the stud into the base metal 2010 MIDWEST FASTENERS INC UA500 Stud Welding System FIRST TEST WELDS Before you begin to weld anytime it is important to review the set up
22. round base of stud Fillet has a shiny surface and smooth serrations around edge Stud burn off of 1 8 or more HOT WELD Low concave fillet with shiny surface SOLUTION Decrease time current or both COLD WELD Fillet complete but with gray grainy surface and a few stringers SOLUTION Decrease time current or both HANG UP Ferrule so far off center from weld end of stud that stud catches on edge of ferrule and is not driven into pool of molten metal SOLUTION Realign ferrule Continues gt 2010 MIDWEST FASTENERS INC UA500 Stud Welding System Testing of weld guality beyond visual inspection varies with stud characteristics Refer to AWS American Welding Society structure welding code AWS d 1 rev 1 76 Welding procedures are covered in sections 4 28 and 4 29 Weld test and inspection is covered in section 4 30 paragraphs 1 through 4 American Welding Society 2501 N W Tth street Miami FL 33125 A bend test may be used to test weld results if the stud may be destroyed This is usually done with a bending tool a hollow pipe with an inside diameter just large enough to fit over the diameter of the stud The bend tool is placed over the stud down to the base material The stud is then repeatedly bent away from its axis until failure occurs Torgue test maybe used on threaded studs The stud 1s twisted to the point of failure A twisting tensile load is applied by using a collar w
23. rrule grip are needed for each different stud diameter and style that will be welded The appropriate chuck is inserted into the tapered chuck adaptor The ferrule grip is inserted in the hole in the foot and secured with the locking screws to hold it in place CHUCK REMOVAL amp INSTALLATION To install a chuck position the chuck into the front of the chuck adapter Tap lightly on the end to seat the chuck into the adapter It is not necessary to pound on the end of the chuck This will only damage the chuck itself INSTALLING A CHUCK Tap firmly y YZ chuck into chuck adapres Iris pot necessary obama ca ce bead the chuck into posi ion E There is also a depth stop inside of the chuck The depth stop should be adjusted so that you are retaining a good portion of the stud you are setting up to weld Typically this is one third to one half of the length of the stud you are welding To remove the chuck insert the short tapered end of the chuck ejector key into one of the holes in the side of the chuck adapter You may have to move the rubber bellows to clearly see the holes in the side of the chuck adapter under rubber boot Rotate the chuck key either clockwise or counter clockwise and the chuck will pop out of the chuck adapter REMOVING A CHUCK FOOT amp LEG SET UP The foot comes in 3 different sizes small medium and large and 2 different configurations closed and split Typically a split foot is only us
24. the set screws in the foot Tighten the set screws to retain the ferrule grip It is not necessary to make these extremely tight When a spark shield is being used it is not necessary to align the spark shield with the set screws in the foot FOOT ALIGNMENT Alignment of the foot is very important if the foot is not aligned properly it can create bad welds in the form of hang ups Place a stud into the chuck and a ferrule into the ferrule grip The stud should sit perfectly in the center of the ferrule If it does not loosen the flat head screws on the legs holding the foot Position the foot so the stud is perfectly aligned in the ferrule Retighten the flat head screws FOOT ALIGNMENT Enaralo Farus Grip PLUNGE ADJUSTMENT Plunge Settings When Using Ferrules Plunge controls the amount of stud that is melted during the arc time Too much plunge and the fillet will overfill the ferrule or create excessive splatter when using a spark shield Too little plunge and there may be incomplete fillet formation There should be approximately 1 8 of an inch of stud protruding past the end of the ferrule A bit less for smaller studs a bit more for larger studs Stud Diameter Plunge 25 625 125 75 and up 188 To adjust the plunge loosen the leg set screws in the gun body Move the foot towards the gun or away from the gun to increase or decrease plunge The plunge measurements are from the end of the stud and do not include th
25. tion ADDITIONAL SAFETY INFORMATION The following organizations can provide detailed information on safe practices for electric arc welding American Welding Society 550 NW LeJuene Road Miami FL 33126 305 443 9353 www aws org National Fire Protection Association 1 Battery March Park Quincy MA 02269 9101 617 770 3000 www nfpa org and www sparky org Canadian Standards Association 178 Rexdale Blvd Rexdale Ontario CAN M9W 1R3 800 463 6727 www csa international org American National Standards Institute 11 W 42nd Street New York NY 10036 8002 212 642 4900 www ansi org U S Government Printing Office Superintendent of Documents PO Box 371954 Pittsburgh PA 15250 312 353 2220 www osha gov PROTECTION HEARING PROTECTION PROTECTIVE CLOTHING HIGH VOLTAGE FIRE HAZARD 2010 MIDWEST FASTENERS INC UA500 Stud Welding System WHAT IS ARC STUD WELDING Stud welding is a welding process where a stud or similar metal part is instantaneously end joined to a metal workpiece This process involves the same basic principles and metallurgical aspects as any other welding process The eguipment reguired to stud weld is composed of a direct current power supply a controller a weld gun and cables to tie the system components together In most systems the power supply and controller are combined into one unit called the Welder UA500 STUD WELDING SYSTEM P N OEUA 500 Power Supply
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