Miller | LF033066 | Owner Manual | Miller POWCON ARC STUD 625 User manual

Miller POWCON ARC STUD 625 User manual
OM-216 244D
October 2004
Process
Stud (SW) Welding
Description
Arc Welding Power Source
R
PowCon
Arc Stud 625
Welding System
R
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 7/03
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION - POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Weld Output Receptacles And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. 4 Pin Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION - STUD GUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Chuck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Chuck Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Foot and Leg Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Ferrule Grip / Spark Shield Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Foot Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Connecting Stud Gun and Work Clamp to Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Plunge Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Adjusting Gun Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION - POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Time/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Rack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − OPERATION - STUD GUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Stud Gun Tool Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Stud Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Welding Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Recommended Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Maintenance Procedures for Stud Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Troubleshooting Help Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Troubleshooting - Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Troubleshooting - Stud Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST FOR POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST FOR STUD GUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − OPTIONS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-216 244 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-216 244 Page 2
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-216 244 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-216 244 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie « NOTA » ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
2-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 2-4.
Lire et respecter toutes ces normes.
D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D
Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi−automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D
D
D
Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.
Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).
D Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé−sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respirable.
D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en
présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.
OM-216 244 Page 5
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
LE SOUDAGE peut causer un incendie ou une explosion.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et
s’assurer que l’endroit ne présente pas de danger.
D Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer toutes les substances inflammables à une distance de 10,7 m
de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porte−
électrode ou couper le fil au raz du tube−contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peuvent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-216 244 Page 6
LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même
la mort.
D
D
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.
LES PIÈCES CHAUDES peuvent causer des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimulateurs cardiaques.
D
D
Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D
Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
Les BOUTEILLES
peuvent exploser.
endommagées
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un porte−bouteilles pour les empêcher de tomber ou de se
renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P−1 de la CGA,
mentionnées dans les normes de sécurité.
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLOSION
LES ORGANES MOBILES peuvent
causer des blessures.
D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.
D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre
l’appareil en service.
LA CHUTE DE L’APPAREIL peut
blesser.
D N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimés.
LES PIÈCES MOBILES peuvent causer des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.
LES FILS DE SOUDAGE peuvent causer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en engageant le fil de soudage.
LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des
interférences.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.
LE SOUDAGE À L’ARC peut causer
des interférences.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
D En cas d’interférences après exécution des directives précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-216 244 Page 7
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443−9353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.
OM-216 244 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
SECTION 3 − INTRODUCTION
3-1. Specifications
Rated Welding Output
1000 A at 36 VDC,
3-Phase
7% Duty Cycle
Amperage
Range in
CC Mode
Max. OpenCircuit
Voltage
50−1000A
70 VDC
RMS Amps Input at Rated Load
Output, 60 Hz 3-Phase at NEMA
Load Voltages and Class I Rating
480 V
575 V
KVA
KW
55
(0.10*)
45
(0.08*)
46
(0.09*)
42
(0.04*)
*While idling
**See Section 4-2 for additional information.
3-2. Duty Cycle And Overheating
Y Exceeding duty cycle can
damage unit and void
warranty.
Percent duty cycle = 1.7 times the
number of 1 second (1000ms)
loads/outputs per minute, without
overheating. The one second load
is the rated output.
0.750
STUD SIZE
0.625
If unit overheats, output stops. A
HLP 3 message (see Section 8-4)
is displayed, and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or duty cycle before welding.
0.500
0.375
0.250
0.125
0.000
4
10
30
40
60
NUMBER OF STUDS IN ONE MINUTE
7% Duty Cycle
1 second Welding
14 seconds Resting
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
sduty1 5/95 / SA-207 877
OM-216 244 Page 9
SECTION 4 − INSTALLATION - POWER SOURCE
4-1. Selecting a Location
24 in
(610 mm)
Dimensions And Weight
73 lb (33.1 kg)
17 in
(432 mm)
12-1/2 in
(318 mm)
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
Movement
Y Do not move or operate unit
where it could tip.
1
1
Lifting Handles
Use handles to lift unit.
2
1
Hand Cart
Use cart or similar device to move
unit.
2
3
Rating Label
Use rating label to determine input
power needs.
4
Line Disconnect Device
Locate unit near correct input
power supply.
Location
4
18 in
(460 mm)
3
18 in
(460 mm)
OM-216 244 Page 10
loc_2 3/96 - Ref. ST-151 556 / 803 618-A
4-2. Electrical Service Guide
Y
CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding pow-
er source requires a CONTINUOUS supply of 60 Hz (+10%) power at +10% of rated input voltage. Do
not use a generator with automatic idle device (that idles engine when no load is sensed) to supply
input power to this welding power source.
NOTE
Actual input voltage should not exceed ± 10% of indicated required input voltage. If
actual input voltage is outside of this range, output may not be available.
60 Hz Three Phase
Input Voltage
480
575
Input Amperes At Rated Output
55
45
60
50
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2
Normal Operating 3
Min Input Conductor Size In AWG
4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
10
10
175
(53)
274
(83)
10
10
Reference: 1999 National Electrical Code (NEC)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
Notes
OM-216 244 Page 11
4-3. Weld Output Receptacles And Selecting Cable Sizes
Y ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Weld Output
Terminals
Y Turn off power before connecting to
weld output terminals.
Y Do not use worn, damaged, undersized,
or poorly spliced cables.
(Work)
(Gun)
Arc Stud Size & Welding Current (Shank Size)
Output Receptacles
1”
7/8”
2100
1900
1800
Use multiple 4/0 cables or
500 mcm cable or larger.
2-4/0
1700
1600
1500
3/4”
1400
4/0
1300
5/8”
1200
1100
1000
1/2”
7/16”
3/8”
5/16”
1/4”
2/0
900
800
700
600
500
400
No. 1
Cable Size
Area
300
50
100
150
200
250
300
350
400
TOTAL CABLE LENGTH (FT)
(Ground And Electrode)
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
OM-216 244 Page 12
4-4. Connecting 3-Phase Input Power
Y Installation must meet all National
and Local Codes − have only qualified persons make this installation.
Y Disconnect and lockout/tagout input power before connecting input
conductors from unit.
3
= GND/PE Earth Ground
Y Always connect green or green/
yellow conductor to supply
grounding terminal first, and never to a line terminal.
. The Auto-Line circuitry in this unit au-
4
tomatically adapts the power source
to the primary voltage being applied.
Check input voltage available at site.
This unit can be connected to any input power between 480 or 575 VAC
without removing cover to relink the
power source.
7
1
2
2
3
4
L1
3
L2
5
L3
6
5
6
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
Green Or Green/Yellow Grounding
Conductor
Disconnect Device Grounding
Terminal
Input Conductors (L1, L2 And L3)
Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2, and L3
to disconnect device line terminals.
7
1
Overcurrent Protection
Select type and size of overcurrent protection using Section 4-2 (fused disconnect
switch shown).
1
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
2/04 - Ref. 802 136-A
OM-216 244 Page 13
4-5. Circuit Breaker
1
Circuit Breaker CB1
CB1 protects 60 volts ac portion
of Remote 4 pin receptacle from
overload.
Press button to reset breaker.
1
803 619-A
4-6. 4 Pin Receptacle Information
CONTROL
Socket
Socket Information
4
3
GUN
CONTROL
2
1
3
1
Notes
OM-216 244 Page 14
Output to control of gun solenoid; 90 volts dc.
2
4
Contact closure between 3 and 4 initiates weld
cycle.
SECTION 5 − INSTALLATION - STUD GUN
5-1. Chuck Installation
Y Disconnect gun from power
source before installing or
removing components.
1
2
Chuck
Chuck Adapter
To install chuck, align chuck in front
of chuck adapter. Tap firmly on the
end of chuck to seat chuck into
adapter. Not necessary to pound
on the end of the chuck. This will damage the chuck.
Do not hammer or beat
chuck into position.
. There is a unique chuck for ev-
ery diameter of stud. Rectangular and other special shape
studs may require specialized
chucks. 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 being welded.
2
1
5-2. Chuck Removal
1
2
Chuck Key
Hole - Chuck Adapter
To remove chuck, insert short, tapered end of chuck ejector key into
one of the holes in the side of the
chuck adapter. It may be necessary
to move the rubber bellows to see
the holes in the side of the chuck
adapter.
Rotate chuck key clockwise or
counter clockwise and the chuck
will pop out of the chuck adapter.
. Chuck is held into the chuck
2
adaptor with a #2 morse taper.
1
OM-216 244 Page 15
5-3. Foot and Leg Setup
Foot Installation
1
2
3
4
5
5
3
Leg Screw
Leg Washer
Ferrule Grip
Foot
Leg
The foot is available in 3 different sizes
(small, medium, and large) and 2 different
configurations (closed and split). Typically, a
split foot is only used when welding headed
anchors and sheer connectors.
1
2
4
Foot Size
Stud Range
Part #
Small
Up to 1/2 in.
219670
Medium
5/8 to 3/4 in.
219671
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.
Make sure flat side of legs face
outside ot gun body to ensure
alignment with set screws.
Leg Installation
6
7
6
Flat Side of Leg
Leg Set Screw
Insert legs into leg retainers. Line up the f lat
side of the legs with set screws Tighten set
screws securely.
7
5-4. Ferrule Grip / Spark Shield Removal and Installation
1
Ferrule Grip
There are 3 set screws that retain the ferrule
grip or spark shield in the foot. Loosen all 3
set screws.
1
Push the ferrule grip or spark shield into the
foot. Press ferrule grip f irmly into the foot so
it seats against the back stop. Line up the 2
side holes in the ferrule grip with set screws
in the foot. Tighten set screws securely.
. If a spark shield is being used, it is not
necessary to align the spark shield with
the set screws in the the foot.
OM-216 244 Page 16
5-5. Foot Alignment
1
2
3
4
5
4
3
2
5
Leg Screw
Foot
Ferrule
Ferrule Grip
Stud
. 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.
1
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 not, loosen the
f lat 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.
5-6. Connecting Stud Gun and Work Clamp to Power Source
Perform the following procedures when
connecting stud gun to power source:
2
•
Connect weld cable
•
Connect control cable
. Use the same instructions provided if
1
connecting to an extension cable.
Connecting Weld Cable and Work
Ground Cable
1
2
Flat
Keyway
To connect to receptacle, align keyway, insert connector, and turn clockwise (approximately 1/2 turn).
Connect stud gun to black output terminal
labeled gun.
Connect work cable to black output terminal
labeled work.
Connecting Control Cable
3
4
4
3
Key
Keyway
Align key in end of control cable with key
way inside connector on front of power supply. Push the connectors together. Turn retaining nut on control cable clockwise.
When nut is snug the connection is complete.
To remove, unscrew connector counter
clockwise.
Ref 802 385-A
OM-216 244 Page 17
5-7. Plunge Adjustment
Plunge Settings When Using Ferrules
1
Plunge controls the amount of stud that is
melted during the arc time. Too much plunge
and the f illet will overf ill the ferrule or create
excessive splatter when using a spark
shield. Too little plunge and there may be incomplete f illet 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
1
2
2
Plunge
0 - .25
.094
.25 - .625
.125
.75 and up
.188
Set Screw
Plunge Depth
To adjust plunge, loosen leg set screws on
gun body. Move foot towards gun or away
from gun to increase or decrease plunge.
Plunge measurements are from end of stud
and do not include the f lux load.
. These instructions are for standard fer-
rules. For reduced f illet ferrules (only
recommended for very specif ic applications) decrease the amount of plunge by
half.
Plunge Settings For Short 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 in (1 mm). This is about
the same as the flange thickness on f langed
style studs. For standard time duration Gas
Short Arc the plunge should be set at about
2 f lange thicknesses or 0.08 in (2 mm).
Notes
OM-216 244 Page 18
5-8. Adjusting Stud Lift
The lift controls the arc length and is a factor
in controlling the heat of the welding process.
Lift should be set at 3/32 or .094 in (2.5 mm).
Measuring LIft
LIft Adjustment Table
1/16 in (1.6 mm) lift for studs up to 5/16 (7.9 mm) diameter
3/32 in (2.4 mm) lift for studs over 5/16 (7.9 mm) to 1/2 in (13 mm) diameter
1/8 in (3.2 mm) lift for studs over 1/2 (13 mm) diameter
Y For safety from accidental activation,
always disconnect the weld cable
from the power source before making
any stud gun adjustments or performing any service on the stud gun.
1
Stud Lift Measurement
To measure stud lift, hold a scale against
some fixed part of the tool. The front cover or
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.
Adjusting Lift
1
2
Location of Core Set Screws
To adjust lift, remove the slotted screw holding the rear cap in place. Remove rear cap.
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
equals .025 in (0.6 mm).
Once lift is set, retighten nylon tipped set
screw to keep the adjustable core in place.
Install rear cap and tighten cap screw.
. Keep cap in place to prevent dirt from entering the stud gun mechanism
2
2
OM-216 244 Page 19
SECTION 6 − OPERATION - POWER SOURCE
6-1. Front Panel Controls
4
3
2
Time (ms)
Amperage
5
6
READY
OUTPUT ON
POWER
1
7
SELECT
ADJUST
CONTROL
GUN
WORK
216 221-A
1
Time/Amperage Select Button
2
Power Switch
Use switch to turn unit On/Off.
3
Time Indicator Meter
OM-216 244 Page 20
4
(LED indicates when meter is active for
adjusting)
Amperage Indicator Meter
(LED indicates when meter is active for
adjusting)
5
READY to Weld Indicator Light
6
OUTPUT ON Indicator LIght
7
Time/Amperage Control
(see Section 6-2)
6-2. Time/Amperage Control
1
TIME (ms)
Time/Amperage Select Button
Depress button to select Time/Amperage control.
AMPERAGE
3
2
2
3
4
Time Meter
Amperage Meter
Time/Amp Adjustment Control
Rotate knob clockwise to increase
time/amperage
S Time - (50-999 milliseconds)
S Amperage - (50-999 amps)
Increase increments by units of 10.
Decrease increments by units of 1.
4
1
SELECT
TIME/AMP ADJUSTMENT
Ref. 216 221-A
6-3. Rack Mounting
This unit is capable of being rack mounted (Contact your distributor).
Notes
OM-216 244 Page 21
SECTION 7 − OPERATION - STUD GUN
7-1. Stud Gun Tool Functions
Y Disconnect gun from power source
before installing or removing components.
The stud gun automates the stud welding
process.
Several key functions are:
• Holds the ferrule, spark shield or gas delivery system
• Holds the stud
• Strikes the arc
• Establishes the arc length (lift distance)
• Thru the power source, the gun controls
the arc time
• Controls rate of plunge of the stud into
the base metal
7-2. Stud Welding Procedures
. Before welding it is important to review
the set up. Correct set up will produce
the best welding results. Approximately
95% of all stud welding problems are
due to improper gun set up or power settings.
Welding Procedures:
•
Place stud to be welded into weld chuck.
• Insert a ferrule into the ferrule grip (this
step is not necessary if using a spark shield)
• Position end of stud in location to be
welded.
• Press gun downward so the ferrule is sitting on the base metal.
•
Pull trigger to begin weld sequence.
•
Hold gun still during the arcing process.
• After weld is complete, continue to hold
the gun still for 1 second to allow the molten
metal to solidify.
Ferrule
Position tool
Press tool towards
against work
work until ferrule
is against work
OM-216 244 Page 22
• Remove the gun from the welded stud.
Be sure and pull the gun straight off of the
welded stud to prevent damage to the weld
chuck.
• Break away the ferrule and inspect the
weld. (Only applies if ferrule was used)
7-3. Welding Sequence
Chuck
Stud
Ferrule
Gun is properely
positioned and main
gun spring is partially
compressed.
Trigger is pressed and the
stud lifts off the work. An
arc is created and melts the
stud and parent material.
After arcing is complete,
the main spring plunges
the stud into the molten
pool of metal.
Gun is withdrawn
from the welded stud.
The ferrule is broken
away and discarded.
7-4. Recommended Settings
STANDARD TABLE
METRIC TABLE
Stud Size
Current
Time
Stud Size
Current
Time
1/4 Inch
300 Amps
.220 Seconds
6 mm
350 Amps
.250 Seconds
5/16 Inch
410 Amps
.300 Seconds
8 mm
420 Amps
.310 Seconds
3/8 Inch
520 Amps
.360 Seconds
10 mm
580 Amps
.430 Seconds
1/2 Inch
750 Amps
.450 Seconds
12 mm
720 Amps
.500 Seconds
5/8 Inch
980 Amps
.730 Seconds
14 mm
880 Amps
.590 Seconds
3/4 Inch
1325 Amps
.750 Seconds
16 mm
1040 Amps
.660 Seconds
7/8 Inch
1680 Amps
.830 Seconds
20 mm
1440 Amps
.780 Seconds
1 Inch
2000 Amps
.870 Seconds
24 mm
1900 Amps
.850 Seconds
The recommended settings are provided as initial settings. Settings may vary per specifications of application. Material surface condition along with lift
and plunge adjustments will vary exact settings.
S Material surface at weld location should be free of dirt, rust and paint.
S Typical adjustments for lift is 3/32 in and plunge is 1/8 in (see Sections 5-7 and 5-8).
S Adjust recommended settings as needed.
OM-216 244 Page 23
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Routine Maintenance
. Maintain more often
Y Disconnect power
before maintaining.
during severe conditions.
3 Months
Repair Or
Replace
Cracked
Cables
Replace
Damaged Or
Unreadable
Labels
Replace Cracked
Stud Gun Body
Repair Or Replace
Cracked Cables
And Cords
Clean
And
Tighten Weld
Connections
6 Months
Blow Out Inside
8-2. Blowing Out Inside Of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
803 618-A
OM-216 244 Page 24
Notes
OM-216 244 Page 25
8-3. Maintenance Procedures for Stud Gun
14
29
13
30
27
26
12
8
25
11
6
5
4
24
10
28
9
4
27
3
2
7
23
22
21
23
20
1
19
33
18
35
17
16
36
15
31
32
37
34
When is Maintenance Required?
Maintenance requirements will vary with environment and usage. Dirty
work areas or high volume stud welding will require more frequent maintenance.
There are three primary reasons for maintenance:
• Dirt - Dirt can enter the lifting mechanism and cause erratic lift and
plunge operations. Typically , cleaning is all that is required.
• Wear - Components do wear out over time. Typically, items such
as plastic bearings or cables wear out and need to be replaced.
• Improper Use - Components can arc out by inadvertently placing
them against grounded materials during a weld sequence. Also, by using the gun as a hammer to test welds will damage parts and require
maintenance.
38
40
41
39
Maintenance Steps
Proper Maintenance Procedures:
• Disassemble the gun.
• Inspect all parts for wear or damage.
• Replace worn or damaged components.
• Clean all components.
• Reassemble components.
• Adjust settings and test.
Disassembly / Assembly Procedures:
Y To prevent accidental activation disconnect the gun from the
power source before adjusting or servicing the gun.
. Remove all accessories from gun before servicing.
. Items referenced ( ) will correspond with list items.
1
2
3
Legs: Loosen set screws (23) and pull legs (not shown) straight out.
Inspect legs for damage and straightness, replace if necessary.
Chuck (Not Shown): Insert chuck key into chuck adapter and turn
key 180 degrees. Inspect chuck for damage. If taper on chuck
appear worn out replace chuck.
Dust Bellows (3): Remove dust bellows by sliding over end of chuck
adapter. The bellows prevent contaminates from entering the
internal mechanisms of the gun. If bellows has holes or is torn,
replace.
OM-216 244 Page 26
42
4
Chuck Adapter (2): Unscrew chuck adapter counter clockwise from
cable clamp adapter. Important that chuck adapter is tight on cable
clamp adapter to form a tight connection. An effective way of
removing the adapter is to insert a round rod through two of the
chuck eject holes.
Replace chuck adapter if inside surface or threads are pitted or
damaged.
5 Front Cover Nuts (1): The front cover is held on with two nuts. Use
a 3/4 inch wrench to remove them. Inspect the plastic bearing (4)
for damage or excessive wear.
6 Front Cover (5): If gun is equipped with a plunge dampener it is
located in the front cover. Inspect front cover for cracks and replace
if cracked. The front cover prevents dirt from entering the internal
mechanism and maintains alignment of internal components.
7 Plunge Dampener (7): The dampener is inside the front cover. It
pulls straight out and pushes straight back in. When the plunge
dampener is activated by a f inger it should offer continuous
resistance over the entire range of travel. The plunger should then
return, by itself, to full extension. If this is not the case the dampener
needs to be replaced.
8 Cable Clamp Adapter (8): Remove two #10−32 x 5/8 socket head
cap screws (6) from cable clamp adapter. The cable clamp adapter
will separate from the lifting rod. Maneuver the cable clamp adapter
forward between the leg inserts. Remove the #8−32 x 1/2 cap
screw (11) from the back of the cable clamp adapter (8).
Inspect threads on cable clamp adapter. If threads are damage replace cable clamp adapter. This item transfers all the weld current.
If there is damage to the threads, arcing will continue and potentially fuse all the components together.
9 Lifting Mechanism: The lifting mechanism consists of the lifting rod
(12), main spring (13), lift release (14), moveable core (15−20) and
core return spring (21). To disassemble, press the lift release ring
tight against the moveable core and pull the lifting rod out of the
assembly. All components listed above, will come apart.
10 Lifting Rod (12): Inspect lifting rod for wear or damage. The brass
inserts should show no signs of loosening. The steel shaft should
not have any nicks on it. Run a finger over the shaft. If you can feel
grooves from the lifting bearing then the lifting rod is worn out.
Typically the lifting rod and lift bearing should be replaced as a set.
When reassembling, the shaft should have a light film of grease (a
lithium based grease) applied.
11 Disassembly of Moveable Core (15 - 20): Remove snap ring (20)
from shaft (18) of core assembly. The snap ring acts as a spring
seat and is important to maintain proper spring tension. Where the
core assembles into the bearing housing is another retaining ring
(19). This retaining ring can be removed with a small f lat bladed
screw driver. After removing the second retaining ring the bearing
housing (15) will separate from the core shaft. The lift bearing (16)
and the lift bearing spring (17) can now be removed.
When reassembling the lift bearing cage must oriented toward the
lift bearing spring. Put a light film of grease (such as a lithium based
grease) over the lift bearing and the lift bearing spring.
12 Handle Covers (35): Remove 3 flat head screws (36 - 37) that retain
the handle cover. Inspect handle cover for breakage.
13 Weld Cable (40): The weld cable can lift out of the gun body. Be
careful unthreading the internal weld cable (9) from inside the body.
The internal and external weld cables can be unscrewed from the
weld cable anchor plate (32). Note the orientation of the weld cable
anchor plate. The radius corner goes toward the top of the body.
Inspect the internal weld cable for frayed or broken wires. If starting
to fray, the internal cable should be replaced.
Inspect weld cable for fraying. Also inspect strain relief (38) for
tears. Inspect cable jacketing for breaks, cuts or tears. If cable
shows signs of damage or wear it should be replaced. In addition,
inspect the weld−lok connector (39). If pitted or damaged, replace.
Inspect weld cable to camlok joint to ensure there is no fraying of
the weld cable.
14 Control Cable (42) (if desired): The control cable is removed by
cutting the wires by the splice connectors. Inspect the control cable
for damage. This includes the strain relief (41) and the insulating
jacketing. If damaged, replace the control cable.
When reinstalling the control cable, there are typically two different
color schemes.
Scheme one: Black and White wires connect to the trigger - Blue
and Brown Wires connect to the coil
Scheme two: Black and White wires connect to the trigger - Red and
Green wires connect to the coil.
Make sure all crimp connections are tight and there is no opportunity for electrical shorting.
15 Trigger Switch (31): The trigger switch is a screw in style. Grabbing
it can be difficult. A 1/2” collet is the ideal removal tool. Use an ohm
meter to check trigger functionality.
16 Rear Cap (29): Unscrew and remove. The rear cap prevents dirt
and other contaminates from entering into the gun mechanism.
. Do not use rear of gun as a hammer to check quality of stud weld
for this will damage the rear cap.
17 Adjustable Core (28): Loosen nylon tipped set screw (27) in rear coil
yoke which holds the adjustable core. Completely unscrew and
remove adjustable core.
18 Rear Coil Yoke (26): Loosen the nylon tipped set screw retaining the
rear coil yoke. To perform this the hex key will have to go into the
opening on an angle to reach the set screw. Once the retaining
screw is loosened use a large wrench to unscrew the rear coil yoke.
19 Coil (25): Coil wires (black and red or green and red inside the gun
handle) must be cut prior to coil removal. Cut wires inside the
handle. After coil wires are free, the coil can be pulled straight out
the rear of the gun. Coil condition - check to make sure there is no
varnish odor (a sign of overheating), heavy discoloration (another
sign of overheating) and verify coil resistance at 19 ohms +/− 1 ohm.
20 Front Coil Yoke (24): In front of the coil is the front coil yoke. This
is a tight f it and may be diff icult to remove. The front coil yoke
contains a plastic bearing (4). This bearing should be inspected for
wear or damage and replaced if necessary. During reassembly,
make sure the bearing f lange is seated in the counterbore on the
front coil yoke. When putting the front coil yoke back into the coil
can, make sure the bearing f lange is facing rear of gun.
Tools Needed:
3/4 in
OM-216 244 Page 27
8-4. Troubleshooting Help Aids
1
2
Ready LED
Output LED
1
2
803 618-A
Front Panel
Error Indication
Output LED Status
Possible Symptom
Remedy
Normal/None
On
No problem
N/A
HLP 1
Off
Malfunction in the primary power circuit.
Contact a factory authorized service
agent.
HLP 2
Off
Malfunction in the thermal protections
circuitry.
Contact a factory authorized service
agent.
HLP 3
Off
Unit has overheated.
Unit has shut down to allow the fan to
cool it (See Section 3-2). Operation
will continue when the unit has cooled.
HLP 4
Off
Trigger circuit is closed when unit was
powered on.
Open trigger circuit and cycle power.
HLP 5
Off
The unit has sustained an Open Circuit
Voltage for more than 10 seconds.
Cycle power. Apply a welding load. If
problem persists, contact a factory authorized service agent.
HLP 6
Off
Input voltage is either under/low voltage or high/over voltage.
Unit has automatically shut down. Operation will continue when input voltage
is within an acceptable limit. Have an
electrician check the input voltage.
DC bus voltage imbalance.
If input voltage is correct, contact authorized factory service agent.
8-5. Troubleshooting - Power Source
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 4-2).
Check and replace line fuse, if necessary, or reset circuit breaker (see Section 4-2).
Check for proper input power connections (see Section 4-2).
No weld output.
Input voltage outside acceptable range of variation (see Section 4-2).
Unit overheated. Allow unit to cool with fan On (see Section 3-2).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 4-3).
Clean and tighten all weld connections.
OM-216 244 Page 28
8-6. Troubleshooting - Stud Gun
Trouble
Hang up - Stud looks like it’s sitting on
a pedestal with an hour glass shape
Remedy
Check alignment of the foot.
Service the gun to ensure lift/release actions are functioning properly.
Undercutting or lack of fillet
Too little plunge. Increase amount of stud extending past end of ferrule or spark shield.
Too little weld time or current. Check Section 7 for base line power recommendations.
Splatter or BB’S emitting from the weld
zone.
Too much plunge. Decrease amount of stud extending past end of ferrule or spark shield.
Dampener Required. If you have a dampener the dampener may have worn out and need replacement. See optional equipment in Section 12.
Too much Current or Time. Check Section 7 for base line power recommendations.
Stud breaks off and weld zone looks
”crystalized”
Not enough weld current or time. Check Section 7 for base line power recommendations.
Bubbles in weld fillet
If you are attempting short arc you may not be able to eliminate this condition. To improve this situation shorten time and increase current. If the results continue to be unsatisfactory then you may need
to add a shielding gas.
Check gas flow/type of shielding gas.
If using flux loaded studs, check to make sure there is a flux load present in the end of the stud.
No lift
Check gun coil connections.
Check for gun coil short or open. There should be 19 ohms of resistance in the gun coil.
Check adjustable core and make sure it is not bottomed out (turned into far clockwise).
Check trigger circuit for opens and shorts.
Short stud and cant get enough to extend past the ferrule
Adjust the internal stop in the chuck.
Arc Extinguishes, or just get a tiny arcbut no weld
Too much lift. Review set up procedures in Section 5.
Check ground path from the power source. All joints must be very tight.
No weld
Broken weld cable.
Broken or bad ground cable/connection.
Check gun lift.
Gun shaft does not move freely when
compressed by hand
Dirt is binding the mechanism. Service gun
Gun spindle is sloppy and has allot of
free play
Front bearing may be worn out or missing. Replace bearing.
Front cover may be loose. Tighten nuts.
OM-216 244 Page 29
Notes
OM-216 244 Page 30
SECTION 9 − ELECTRICAL DIAGRAMS
216 211-E
Figure 9-1. Circuit Diagram For 460/575 Volt Models
OM-216 244 Page 31
37
SECTION 10 − PARTS LIST FOR POWER SOURCE
36
. Hardware is common and
31
9
30
39 38
29
26
42
11
43
48
49
44
50
47
11
12
56
57
Figure 10-1. Parts Assembly
OM−216 244 Page 32
61
62
63
1
2
64
60
69
3
62
67
58
65
68
66
55
4
8
5
54
6
53
52
51
7
9
10
14
15
16
13
46
17
45
18
24
19
25
41
21
22
20
23
40
27
28
12
32
33
34
35
not available unless listed.
Ref. 803 724-A
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-1. Parts Assembly
. . . 1 . . . . . . . . . . . . . . +189 140 . . Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 178 551 . . Insulator, Side Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 175 256 . . Insulator, Side Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 208 015 . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . . 138 442 . . Label, Caution Falling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . HD1 . . . . . 216 178 . . Transducer, Current 600A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG9 . . . . 130 204 . . Connector & Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 216 554 . . Bus Bar, Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 175 139 . . Bus Bar, Output Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 7 . . . . . . . . . . . . . . . 196 355 . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . D1,2,3,4 . . . 201 531 . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . . . . . . . . . . . . . 170 647 . . Bushing, Snap-In Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . R1, C5,6
. . . . . . . . R2, C10,11 . . 175 194 . . Resistor/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . RT1,2 . . . . 173 632 . . Thermistor, Ntc 30k Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . . 185 835 . . Label, Warning Exploding Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . . +216 227 . . Windtunnel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 182 445 . . Nut, 1.000npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . CB1 . . . . . 161 078 . . Circuit Breaker, Man Reset 1p 7a 250vac . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . +216 223 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 215 980 . . Bushing, Strain Relief .709/.984 Id X1.375 Mtg Hole . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 215 982 . . Cable, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 216 234 . . Plate, Ident Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 196 002 . . Label, Warning Electric Shock Power Cord . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . 217 392 . . Label, Caution Incorrect Voltage Will Damage Unit . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 216 355 . . Resistor, W/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 212 526 . . Capacitor, Elctlt 1500 Uf 100 vdc Can 1.40 Dia . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . CR1 . . . . . 110 386 . . Relay, Encl 24vac Dpdt 5a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . 087 111 . . Clamp, Capacitor 1.375 Dia Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 192 853 . . Bracket, Mtg Contactor/Capacitor/Pc Board . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . PC1 . . . . . 215 697 . . Circuit Card, Control (480/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG2 . . . . 131 056 . . Connector & Sockets (RC2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 130 203 . . Connector & Sockets (RC3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . 115 094 . . Connector & Sockets (RC4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . . 115 091 . . Connector & Sockets (RC5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG7 . . . . 115 093 . . Connector & Sockets (RC7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . RC10 . . . . 166 679 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . T2 . . . . . . 216 236 . . Transformer, Control (480/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . +216 232 . . Windtunnel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . 153 403 . . Bushing, Snap-in Nyl .750 Id X 1.000mtg . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 31 . . . . . . . . . . . . . . . 025 248 . . Stand-Off, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . . 4
. . . 32 . . . . . . . . . . . . . . . 177 547 . . Bushing, Snap-in Nyl 1.125mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . 185 214 . . Bus Bar, Interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 34 . . . . . CT1 . . . . . 175 199 . . Transformer, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . C1,C2 . . . . 188 446 . . Capacitor, Polyp Film .5 Uf 900 Vac 10% . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 36 . . . . . C3,4 . . . . . 193 738 . . Capacitor, Elctlt 1800uf 500Vdv (480/575) . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 37 . . . . . PC2 . . . . +208 783 . . Circuit Card, Interconnect (480/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG13 . . . . 131 204 . . Connector & Sockets (RC13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG14,21 . . 115 093 . . Connector & Sockets (RC14) (RC21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 126 026 . . Label, Warning Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . . 175 140 . . Bracket, Di/Dt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . 175 482 . . Coil, Di/Dt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 40 . . . . . . . . . . . . . . . 109 056 . . Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 41 . . . . . SR1 . . . . . 179 629 . . Kit Diode, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . PM1,2 . . . . 184 258 . . Kit, Transistor IGBT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . L1 . . . . . . 173 563 . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-216 244 Page 33
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-1. Parts Assembly (Continued)
. . . 44 . . . . . . . . . . . . . . . 207 725 . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . T1 . . . . . . 216 229 . . Transformer, HF (480/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . . 216 529 . . Heat Sink, Rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . . 216 228 . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . . 173 693 . . Foot, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 49 . . . . . . . . . . . . . . . 176 736 . . Screw, Mtg Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 50 . . . . . . . . . . . . . . . 175 132 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . PC3 . . . . . 220 494 . . Circuit Card Assy, Front Panel & Display W/Program . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG11 . . . . 115 091 . . Connector & Sockets (RC2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG18 . . . . 115 094 . . Housing Plug+Skts, (Service Kit) (RC5) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG17 . . . . 115 093 . . Housing Plug+Skts, (Service Kit) (RC4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . FM . . . . . 175 084 . . Motor, Fan 24Vdc 3000Rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . . 178 548 . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 54 . . . . . C7,8 . . . . . 186 543 . . Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 55 . . . . . . . . . . . . . . . 216 220 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . . 129 525 . . Receptacle, Twlk Insul Fem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 57 . . . . . RC1 . . . . . 216 365 . . Receptacle, W/Leads & Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 216 592 . . Nut, Conduit 0.500 Npt 1.135 Od X .180 Thk . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . . 216 221 . . Nameplate, (Order By Model And Serial Number) . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . . 174 991 . . Knob, Pointer 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . . 175 855 . . Door, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . . 175 138 . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . . 216 527 . . Label, (Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . . 216 528 . . Label, Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . . 144 842 . . Actuator, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . . 176 226 . . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . S1 . . . . . 128 756 . . Switch, Tgl 3pst 40a 600Vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . . 134 327 . . Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 68 . . . . . . . . . . . . . . . 199 840 . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 69 . . . . . . . . . . . . . . . 190 125 . . Label, Warning Electric Shock Power Cord . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM−216 244 Page 34
SECTION 11 − PARTS LIST FOR STUD GUN
. Hardware is common and
not available unless listed.
14
29
13
30
27
26
12
8
25
11
6
5
4
24
10
28
9
4
27
3
7
2
23
22
21
23
20
1
19
33
18
35
17
16
36
15
31
32
37
34
38
40
41
39
42
803 815-A
Figure 11-1. Parts Assembly
OM-216 244 Page 35
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Parts Assembly
. . . 1 . . . . . . . . . . . . . . . 217 397 . . Front Cover Jam Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . . . 217 398 . . Chuck Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 217 399 . . Dust Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 217 400 . . Nylon Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 217 401 . . Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 217 402 . . Cable Clamp Adapter Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . 217 403 . . Plunge Dampener Soft (Standard W/Dampener Model) . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 217 404 . . Plunge Dampener Medium (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 217 405 . . Plunge Dampener Hard (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 217 406 . . Cable Clamp Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 217 407 . . Internal Weld Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 217 408 . . Internal Weld Cable - Lock Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 217 409 . . Internal Weld Cable - Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 217 410 . . Lifting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 217 411 . . Main Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 217 412 . . Lift Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . 217 413 . . Moveable Core Bearing Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 217 414 . . Lift Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 217 415 . . Lift Bearing Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 217 416 . . Moveable Core Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 217 417 . . Shaft Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . 217 418 . . Shaft Spring Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 217 419 . . Core Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 217 420 . . Gun Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 217 421 . . Leg Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . . . 217 422 . . Front Coil Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 217 423 . . Gun Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 217 424 . . Rear Coil Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . 217 425 . . Rear Coil Yoke Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . . . . . . 217 426 . . Adjustable Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . 217 427 . . Rear Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . 217 428 . . Rear Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 217 429 . . Trigger Switch Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . 217 430 . . Weld Cable Anchor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . 217 431 . . Anchor Plate Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . 217 432 . . Anchor Plate Kep Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . 217 433 . . Handle Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . . 217 434 . . Handle Cover - Upper Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . 217 435 . . Handle Cover - Lower Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . . . 217 436 . . Weld Cable Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . 129 527 . . Male Weld Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . 217 438 . . External Weld Cable Complete 9 ft (2.7 m) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . . 217 439 . . Cable Strain Relief (.280 Dia Yellow Control Wire) . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . . 217 440 . . Control Cable (Screw Style) Complete 9 ft (2.7 m) . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model aSnd serial number required when ordering parts from your local distributor.
OM−216 244 Page 36
SECTION 12 − OPTIONS AND ACCESSORIES
12-1.Plunge Dampener
The plunge dampener controls how fast the melted stud drops into the molten weld pool.
There are three typical dampeners:
S Soft (D rating)
S Medium (E rating)
S Hard (F rating)
Hard dampeners are typically only used for large diameter, extremely heavy studs.
12-2.Foot and Leg Setup
Foot Installation
6
1
2
3
3
4
5
6
Leg Screw - 195382
Leg Washer - 195381
Ferrule Grip (see
Section 12-4).
Foot (see Section 12-3).
Leg (see Section 12-3).
Chuck (see Section
12-4).
5
4
1
2
12-3.Table For Foot and Legs
FOOT
LEGS
Foot Size
Stud Range
Part Number
Length
Part Number
Small
Up to 1/2 Inch
219670
9 Inch
219655
Medium
5/8 to 3/4 Inch
219671
14 Inch
219656
12-4.Table For Chucks and Grips
CHUCKS
Stud Size
Standard Chuck
1/4 Inch
219658
5/16 Inch
219659
3/8 Inch
219660
7/16 Inch
1/2 Inch
5/8 Inch
GRIPS
Long Chuck
Stud Size
Standard Grip
1/4 Inch
219664
5/16 Inch
219665
3/8 Inch
219666
219661
7/16 Inch
219667
219662
1/2 Inch
219668
219663
5/8 Inch
219669
195371
12-5.Table For Dampener and Chuck Key
DAMPENER
CHUCK KEY
Rating
Part Number
Part Number
D - Rating (Standard)
217403
219672
E - Rating (Medium)
217404
F - Rating (Hard)
217405
OM-216 244 Page 37
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Effective January 1, 2004
(Equipment with a serial number preface of “LE” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue Limited Warranty shall not apply to:
1.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
miller_warr 6/04
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2004 Miller Electric Mfg. Co.
1/04
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