Miller Arc Stud Welding Fundamentals Manual Download Page 5

Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

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.

FALLING UNIT can cause injury.

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.

OVERUSE can cause OVERHEATING

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.

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.

MOVING PARTS can cause injury.

D

Keep away from moving parts.

D

Keep away from pinch points such as drive

rolls.

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.

MOVING PARTS can cause injury.

D

Keep away from moving parts such as fans.

D

Keep all doors, panels, covers, and guards

closed and securely in place.

D

Have only qualified persons remove doors,

panels, covers, or guards for maintenance as

necessary.

D

Reinstall doors, panels, covers, or guards

when maintenance is finished and before re-

connecting input power.

READ INSTRUCTIONS.

D

Read Owner’s Manual before using or servic-

ing unit.

D

Use only genuine Miller/Hobart replacement

parts.

H.F. RADIATION can cause interference.

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.

D

The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

D

If notified by the FCC about interference, stop using the

equipment at once.

D

Have the installation regularly checked and maintained.

D

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.

ARC WELDING can cause interference.

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.

D

To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D

Locate welding operation  100 meters from any sensitive elec-

tronic equipment.

D

Be sure this welding machine is installed and grounded

according to this manual.

D

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.)

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 Gasoline Engines:

Y

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive

harm.

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.

Summary of Contents for Arc Stud Welding Fundamentals

Page 1: ...Arc Stud Welding Fundamentals 003 338B July 2005 Visit our website at www MillerWelds com...

Page 2: ...ntrols 6 2 7 Volt Ampere Curve Constant Current CC Power Source 7 2 8 Duty Cycle Power Source For Constant Current CC Welding 7 2 9 Arc Stud Welding Guns 8 2 10 Pistol Grip Stud Gun Components 8 2 11...

Page 3: ...see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that input pow...

Page 4: ...ibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nea...

Page 5: ...puters and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt ly cor...

Page 6: ...ational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Do...

Page 7: ...such as automotive ship building appliance aero dynamics boilers light or heavy construction preassembled fabrication designs and fit up parts design The process may be utilized on a range of materia...

Page 8: ...welding is a very fast weld done at high amperage The weld requires the rise to peak current within millisec onds However because the weld time is very short typical duty cycles are very low Some non...

Page 9: ...TS 2 8 Duty Cycle Power Source For Constant Current CC Welding 150 35 40 50 60 70 80 90 100 200 250 300 400 500 600 700 DUTY CYCLE RATED OUTPUT 30 25 20 WELDING AMPERES Explanation of charts A nominal...

Page 10: ...rmally weigh between 4 5 lb 2 kg to 9 lb 4 kg with the body being constructed of high impact plastic The stud gun consists of a body trigger and lift mechanism Stud gun accessories consist of a chuck...

Page 11: ...d gun Avoid more than a 5 volts drop in the cables Cable connections and splices are another area to consider Make the best possible electrical and mechanical con nections Use commercially available w...

Page 12: ...le length and tight connections 3 Secondary hook up should be DC straight polarity for steel and stainless steel and reverse polarity for aluminum and magnesium 4 A good ground is essential Use a C cl...

Page 13: ...hed directly to the stud gun The ferrule D Concentrates the arc heat to the immediate weld area D Protects the molten weld pool from atmospheric contamination D Confines the molten metal to the weld z...

Page 14: ...e adjusted to approximate settings shown in stud welding table see Section 3 7 3 7 Recommended Settings For Stud Welding Of Steel STANDARD TABLE METRIC TABLE Stud Size Current Time Stud Size Current T...

Page 15: ...Inspect studs visually or by me chanical testing Problem Poor weld Plunge of stud too short or high amperage Remedy Ensure that stud ex tends 3 32 in to 3 16 in beyond the ferrule Make sure gun action...

Page 16: ...tates Each welding unit before use in production shall be used to weld two stud or shear connectors to separate material in the same general position flat vertical overhead sloping and of similar thic...

Page 17: ...D STUDS Normal Diameter Of Studs Inches mm Threads Per Inch And Series Designated Testing Torque Foot Pounds 1 4 in 6 3 mm 1 4 in 6 3 mm 28 UNF 20 UNC 5 0 4 2 5 16 in 8 mm 5 16 in 8 mm 24 UNF 18 UNC 9...

Page 18: ...Notes...

Page 19: ...auge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKNESS REFERE...

Page 20: ...Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA Canada FAX 920 735 4134 International FAX 920 735 4125 European Hea...

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