Pro-Weld AG-805 Manual de usuario
OPERATION/MAINTENANCE
MANUAL
300-0805
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
6.0
GUN SET
-UP................................................................................................. 3
7.0
WELD TEST AND INSPECTION.............................................................
5
7.1
WELD TEST.................................................................................................
5
7.2 WELD INSPECTION.................................................................................. 5
7.3
CAUSES OF POOR OR ERRATIC WELDS...............…...............…….
5
7.4
TROUBLE SHOOTING POOR WELDS..................................................
7
8.0
MAINTENANCE..........................................................................................
7
8.1
DISASSEMBLY..........................................................……………………..
7
8.2
RE
-
ASSEMBLY…………………………..............................................…..
7
8.3 WELD CABLE REPLACEMENT..……………....................................... 8
8.4 CONTROL CABLE REPLACEMENT..................................................… 8
8.5 GUN MAINTENANCE................................................................................. 8
PARTS LIST GUN ASSEMB
LY ARC STD. LD................…......………. 9,10
9.0 TROUBLE SHOOTING GUIDE............................................................... 11
PRO WELD 300-0805
300-0805
PRO WELD
PRO WELD 300-0805
300-0805
PRO WELD
PRO WELD 300-0805
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
advanc
es, for complete reliable welding of mild
steel, stainless steel, and aluminum.
2.0 WARRANTY
The electrical and mechanical co
mponents of the
stud welder are thoroughly performance inspected prior
to assembly in the welder. The assembled welder is
completely performance checked. The welder is d
e
li
v-
ered to you in functional electro
-
mechanical cond
i
tion.
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 wel
d-
ing 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 p
e-
riod of 3 years.
Under the warranty, the manufacturer reserves
the right to repair or replace, at their option, defective
part
s which fail during the guarantee period. Notice of
any claim for warranty repair or replacement must be
furnished to the manufa
cturer by the purchaser within
ten (10) days after the defect is first discovered. The
manufacturer does not assume any liabilit
y for paying
shipping cost or any labor or materials furnished where
such cost are not expressly authorized in writing.
The ma
nufacturer does not warrant any parts or
accessories against failures resulting from misuse,
abuse, improper installation, malad
justment, or use not
in accordance with the operating instructions furnished
by the manufacturer. The warranty is valid only whe
n
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 pe
r-
sonal safety and to protect those working in the area.
Reference is directed, without endorsement or recomme
n-
dation, 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 ci
r-
cuit conditions, the welding machines output voltage may
be dangerous.
2. Don’t work on live circuits or conductors. Disconne
ct
the main power before checking the machine or perfor
m-
ing any maintenance.
3. Be sure the welding machine cabinet is properly
grounded to a good electrical ground. Consult local ele
c-
tr
i
cal 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 conne
c-
tions. 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
300-0805
PRO WELD
8
. Don’t weld on containers which have held
combustible or flammable materials, or on m
a-
terials which give off flammable or toxic v
a-
pors when heated.
9. Be sure to provide for proper ventilation
when welding in a confined area.
10. Never look at the electr
ic arc without
wea
r
ing 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
AG
-
805 LIGHT DUTY ARC GUN W/DAMPER
(Part No. 300
-
0805)
A shaped to the hand, semi automatic stud welding
tool. Welds any length stud with a diameter range of
12 gauge through 5/8 inches. Refer to figure 4
-
1 for
weight and size s
pecifications.
5.0 UNPACKING
There is very little to do when unpacking your ARC
Stud Welding gun. Your Stud Welder comes co
m-
plete with all the accessories and tool required for
set
-
up, adjustment, and maintenance. Aside from the
correct chuck, ferrule grip, and any special access
o-
ries required for your application your ARC weld
gun is ready for hook
-
up to a Pro Weld power
source.
PAGE 2
Typical working weight gun plus
4 feet of unsupported 1/0 cables ..7 pounds
Shipping weight of gun plus
approximately 8 fee
t of
1/0 cable and connectors....... 11 pounds
Note: Chuck and ferrule grip are not standard
and must be ordered separately.
Figure 4
-
1 Standard AG
-
805 M.D. ARC Gun
1.0
10
6.1
6.6
PRO WELD 300-0805
6
.0 GUN SET
-
UP
The standard gun set
-
up is used for welding the m
a-
jority of applications. It consists of the standard a
d-
justable 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
co
r
rect way to set up the gun. (Refer to Figure 6
-
1)
1. A different, and correctly sized, chuck and ferrule
grip are needed for e
ach 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, fe
r-
rule 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
loosened, the foot will move freely in all directions.
Adjust the foot so that the stud is centered in the fe
r-
rule and no contact occurs between the stud and the
ferrule during retraction or forward plunge of the stud.
Tighten the lockin
g 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 se
t-
ting the plunge and re
-
check centering to be sure the
stud is aligned properly in the ferrule.
4. The lift height, which deter
mines 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 volta
ge 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 di
s-
tance 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
Chuck Adaptor
Chuck
Locking Screws
Ferrule
Plunge Length
Stud
Ferrule Grip
(2) Foot
Screws
Foot
Leg
Leg Adj. Screw
Figure 6
-
1 GUN SET
-
UP
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