PRO WELD INTERNATIONAL AG-900 Manual
OPERATION/MAINTENANCE
OPERATION/MAINTENANCEOPERATION/MAINTENANCE
OPERATION/MAINTENANCE
MANUAL
MANUALMANUAL
MANUAL
H.D. ARC GUN
H.D. ARC GUNH.D. ARC GUN
H.D. ARC GUN
AG
AGAG
AG-
---900
900 900
900
AG-900
PRO WELD
TABLE OF CONTENTS
1.0 INTRODUCTION........................................................................................ 1
2.0 WARRANTY..........................................................................................…... 1
3.0 SUGGESTED SAFETY PRECAUTION................................................... 1
4.0 GENERAL DESCRIPTION........................................................................ 2
5.0 UNPACKING................................................................................................ 2
4.0 GUN SET-UP................................................................................................. 3
7.0 WELD TEST AND INSPECTION............................................................. 7
7.1 WELD TEST................................................................................................. 7
7.2 WELD INSPECTION.................................................................................. 7
7.3 CAUSES OF POOR OR ERRATIC WELDS...............…...............…….. 7
7.4 TROUBLE SHOOTING POOR WELDS.................................................. 9
8.0 MAINTENANCE.......................................................................................... 9
8.1 WELD CABLE REPLACEMENT............................................................. 9
8.2 CONTROL CABLE REPLACEMENT...............................................….. 9
8.3 DISASSEMBLY OF GUN………………………....................................... 10
8.4 GUN MAINTENANCE……………..........................................................… 10
8.5 RE-ASSEMBLY............................................................................................ 11
PARTS LIST GUN ASSEMBLY ARC STD. HD...................................... 12
9.0 TROUBLE SHOOTING GUIDE................................................................ 14
PRO WELD
AG-900
AG-900
PRO WELD
PRO WELD
AG-900
AG-900
PRO WELD
PRO WELD
AG-900
1.0 INTRODUCTION
Your new stud welding equipment is constructed
of the finest components and material available.
Used properly, this equipment will give you years
of profitable, efficient service.
The system incorporates the latest in engineering
advances, for complete reliable welding of mild
steel, stainless steel, and aluminum.
2.0 WARRANTY
The electrical and mechanical components of the
stud welder are thoroughly performance inspected prior
to assembly in the welder. The assembled welder is
completely performance checked. The welder is
delivered to you in functional electro-mechanical
condition.
All parts used in the assembly of the welder and
its accessories are fully warranted for a period of 1
YEAR from the date of delivery. In addition, the
welding capacitors are warranted for a period of 1
YEAR from the date of delivery. The printed circuit
boards used in all proweld equipment are warranted for
a period of 3 years.
Under the warranty, the manufacturer reserves
the right to repair or replace, at their option, defective
parts which fail during the guarantee period. Notice of
any claim for warranty repair or replacement must be
furnished to the manufacturer by the purchaser within
ten (10) days after the defect is first discovered. The
manufacturer does not assume any liability for paying
shipping cost or any labor or materials furnished where
such cost are not expressly authorized in writing.
The manufacturer does not warrant any parts or
accessories against failures resulting from misuse,
abuse, improper installation, maladjustment, or use not
in accordance with the operating instructions furnished
by the manufacturer. The warranty is valid only when
studs are purchased from sources approved by the
manufacturer or are of identical specifications to the
manufacturer’s
3.0 SUGGESTED SAFETY PRECAUTIONS
In any welding operation, it is the responsibility of the
welder to observe all safety rules to insure his or her
personal safety and to protect those working in the area.
Reference is directed, without endorsement or
recommendation, to ANSI Z49.1, Safety in Welding and
Cutting, and to AWG Publication A6-66, Recommended
Safe Practices for Gas-Shielded Arc Welding.
1. Always treat electricity with respect. Under open
circuit conditions, the welding machines output voltage
may be dangerous.
2. Don’t work on live circuits or conductors. Disconnect
the main power before checking the machine or
performing any maintenance.
3. Be sure the welding machine cabinet is properly
grounded to a good electrical ground. Consult local
electrical codes.
4. Never operate a welder in the rain, or operate a welder
while standing in water. Avoid wearing wet or sweaty
clothes when welding.
5. Don’t operate with worn or poorly connected cables,
and don’t operate the weld gun with loose cable
connections. Inspect all cables frequently for insulation
failures, exposed wires, loose connections and repair as
needed.
6. Don’t overload welding cables or continue to operate
with over heated cables.
7. Don’t weld near flammable materials or liquids in or
near the area, or on ducts or pipes carrying explosive
gases.
PAGE 1
AG-900
PRO WELD
8. Don’t weld on containers which have held
combustible or flammable materials, or on
materials which give off flammable or toxic
vapors when heated.
9. Be sure to provide for proper ventilation
when welding in a confined area.
10. Never look at the electric arc without
wearing protective eye shields.
11. Always use the proper protective clothing,
gloves, etc.
12. Never strike an arc when near a bystander
who is unaware of the danger of ultraviolet
light to their eyes.
4.0 GENERAL DESCRIPTION
WELD GUN - STANDARD ARC HEAVY DUTY
(Part No. 300-0900)
A shaped to the hand, semi automatic stud welding
tool. Welds any length stud with a diameter range of
5/8 through 1-1/4 inches. Refer to figure 4-1 for
weight and size specifications.
5.0 UNPACKING
There is very little to do when unpacking your ARC
Stud Welding gun. Your Stud Welder comes
complete with all the accessories and tool required
for set-up, adjustment, and maintenance. Aside from
the correct chuck, ferrule grip, and any special
accessories required for your application your ARC
weld gun is ready for hook-up to a Pro Weld power
source.
Weight (includes standard legs,
foot, and 1/0 cables)............. 6.2 pounds...2.8 kg
Typical working weight gun plus
4 feet of unsupported 4/0 cables ..9 pounds...4.2 kg
Shipping weight of gun plus
approximately 8 feet of
4/0 cable and connectors....... 13.5 pounds...6.1 kg
Note: Chuck and ferrule grip are not standard and
must
be ordered separately.
Figure 4-1 Standard ARC HD Weld Gun
9.5
7”
6”
2”
1”
PAGE 2
PRO WELD
AG-900
6.0 GUN SET-UP
The standard gun set-up is used for welding the
majority of applications. It consists of the standard
adjustable face plate, two legs, a foot, chuck adapter,
chuck, and spring for your specific stud size.
The following is a step by step explanation of the
correct way to set up the gun. (Refer to Figure 6-1)
1. A different, and correctly sized, chuck and ferrule
grip are needed for each different stud diameter and
style that will be welded. The appropriate chuck, or
stud holder, is inserted into the tapered chuck adapter
and tapped lightly to insure a tight fit. The ferrule
grip is inserted in the hole in the foot and secured
with the locking screws to hold it in place.
2. Studs must NOT bind or hang up on the foot,
ferrule grip, or ferrule during the entire stud welding
process. To assure this, the foot/ferrule arrangement
must be centered in relation to the stud to be welded.
To assure centering, loosen the locking screws that
hold the foot to the legs. Place a stud in the chuck
and a ferrule in the grip. With the locking screw
Figure 6-1 GUN SET-UP
loosened, the foot will move freely in all directions.
Adjust the foot so that the stud is centered in the
ferrule and no contact occurs between the stud and the
ferrule during retraction or forward plunge of the stud.
Tighten the locking screws after centering the stud.
3. The “Plunge Length” is the amount of stud exposed
beyond the ferrule during initial set-up. Set the plunge
by loosening the leg adjusting screws and moving the
foot until the stud extends 1/8” to 3/16” past the end of
the ferrule. Tighten the leg adjusting screws after
setting the plunge and re-check centering to be sure
the stud is aligned properly in the ferrule.
4. The lift height, which determines the arc length,
has been pre-set at the factory and will automatically
lift and plunge the stud during the welding process.
“Lift” is the distance the gun will raise the stud above
the welding surface during the weld. This distance
governs the voltage and the arc. Improper lift will
cause unsatisfactory welds.
To measure the lift, turn the stud welding unit on and
set the timer to maximum time. (On certain units there
may be a Lift Check switch available, and in these
cases this switch can be used to check lift.) Trigger
the gun in the air or on a non-grounded or insulated
surface, to observe the lift cycle. Measuring the
distance the stud or gun mechanism moves equals lift.
Usually this can be easily done by visual observation
or simple measurement against a static reference point
(i.e. the ferrule properly seated in the ferrule grip).
PAGE 3
Tabla de contenidos
Otros manuales de Sistema de soldadura de PRO WELD INTERNATIONAL
Manuales populares de Sistema de soldadura de otras marcas
TAFA
TAFA 30*8B35 Manual de usuario
Lincoln Electric
Lincoln Electric INVERTEC V350-PRO CE Manual de usuario
ESAB
ESAB Buddy Arc 145 Manual de usuario
CIGWELD
CIGWELD 636804 Guía rápida
Red-D-Arc
Red-D-Arc DC-400 Manual de usuario
Hobart Welding Products
Hobart Welding Products Spool Gun DP 3035-10 Manual de usuario
