Pro-Weld ARC 1850, Operation Manual

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ARC 1 8 5 0
PRO WEL D
8.0 WELD GUN SET-UP
8.1 Plunge Length
1. A different and correctly sized chuck and ferrule grip are
needed for each different stud diameter and style that will be
welded (see PRO WELD Accessories catalog for help in this
area). 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 se-
cured 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 leg
screws that hold the foot to the legs. Place a stud in the
chuck and a ferrule in the ferrule grip. With the leg screws
loosened, the foot will move freely in all directions. Adjust
the foot so that the stud is centered in the ferrule and no con-
tact occurs between the stud and the ferrule during retraction
or forward plunge of the stud.
3. The “plunge length” is the amount of the stud exposed be-
yond the ferrule during initial set-up. Set the plunge by loos-
ening 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 recheck
centering to be sure the stud is aligned properly in the fer-
rule.
4. The lift height, which determines the arc length, has been
preset 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. Im-
proper lift will cause unsatisfactory welds. Refer to para-
graph 8-1 if it becomes necessary to ad-
5. Make sure that the cables are connected to the power
source (standard set-up is straight polarity - Negative to con-
troller (or gun) and Positive (ground cable) to the work sur-
face).
6. Turn on the power supply and adjust the current and time
for the weld base diameter of the fastener to be welded.
7. Place the gun, loaded with the stud and ferrule, squarely
against the grounded work surface. The main spring in the
gun will take up the “plunge length” and the ferrule will seat
against the base plate.
DO NOT MOVE THE GUN DURING THE WELD
CYCLE
8. Pull the trigger holding the gun completely still as above.
The gun will lift the stud from the base plate and draw an
arc. The end of the stud and the adjacent material of the base
plate, will be melted by the weld arc.
The gun will then plunge the stud into the molten pool, extin-
guishing the arc, to end the controlled portion of the weld
cycle.
9. After the controlled weld cycle, allow the molten metal to
solidify briefly with the work surface to assure completion
of the cycle (about an extra second holding "still" after the
weld is usually sufficient).
10. Remove the gun from the work by lifting straight away
from the welded stud (this will assure better life to the gun's
expendable accessories). The ferrule may now be removed
by breaking it away from the welded stud to allow inspect-
tion of the weld results. After inspection of sample welds the
gun can be adjusted, as per the step in this procedure,
for optimum results.
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