OPERATION/ MAINTENANCE MANUAL
Contents
1. Figure 12 CURRENT CONTROL P C BOARD P N 600 0012 PAGE 15 PRO WELD INTERNATIONAL ARC 3000 10 0 TROUBLE SHOOTING Whenever possible have a qualified electrician do the maintenance and trouble shooting work Turn the input power off us ing the disconnect switch at the fuse box before working inside the machine Trouble Unit trips off without welding Low output Maximum output but no control Gun does not lift Gun lifts but does not weld Gun lifts but does not plunge Display inoperative Possible Cause Defective main SCR Defective sustaining arc SCR Defective 600 0012 P C board Defective 600 0010 P C board Shorted control cables Input fuse blown Unit is single phase Incorrect jumper link connection on primary board Defective 600 0012 P C board Defective 600 0010 P C board Defective current potentiometer Defective 600 0012 P C board 2 Open lead going to shunt shielded cable Defective current Blown 5 amp fuse 2 Defective 600 0010 P C board2. Figure 10 GUN TIME CONTROL BOARD P N 600 0010 PAGE 13 3000 INTERNATIONAL 5020 80640 bag 6224 7059 10280 0240 5 as Os TE 2 ES Z O gt PAGE 14 3000 INTERNATIONAL 2985
3. offal 123456 123456 123456 Figure 1 Jumper Link Arrangement Jumper Link connections Fl 3AMP 600V FUSE P N 120 0007 PRIMARY WIRE DELAY TYPE FUSE CAUTION The stud labeled GND is connected to the unit chassis and is for grounding purposes only Do not connect a wire SIZE AWG GND SIZE IN AMPS 230V 3 0 NO 2 400 from the terminal labeled GND to one of the three phase line terminals as this may result in hot power unit chas 460V NO 1 NO 6 200 575 1 6 200 3 PRO WELD INTERNATIONAL ARC 3000 Figure 2 CONTROL PANEL FRONT DUAL GUN SYSTEM 7 0 CONTROL PANEL DESCRIPTION START STOP PUSH BUTTON Momentarily depressing the START button will energize the main contactor inside the unit allowing all circuits to be acti vated and the the cooling fan to run Momentarily depressing the STOP button will deactivate the entire machine STUD CONSTANT OUTPUT SWITCH When this switch is in the stud position the unit is a dedi cated stud welding power supply with built in time and cur rent controls When in the constant output position the unit becomes a welding power supply that can operate an external control box WELD SETUP SWITCH This switch directs the digital panel meter to display either the setup parameters or the actual weld parameters This switch must be in the weld position for the unit to weld TIME CURRENT SWITCH This switch selec
4. and lockout the gun from retriggering If there is a gun fault by unplugging the gun control cable at the welder the LED will be off when the welder is first turned off then turned back on If there is a thermal overload the LED will remain on until the tem perature on the transformer cools down to a safer operating PAGE 4 zc WELD INTERNATIONAL Le PI unge Length Fenulo Grip ARC 3000 Chuck Adaptor Leg Adj Screw Figure 3 Standard Gun Set up 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
5. Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards MOVING PARTS can cause injury Keep away from moving parts Keep away from pinch points such as drive rolls WELDING WIRE can cause injury Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 ARC 3000 PARTS c cause injury Keep away from moving parts such as fans Keep all doors panels
6. Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Donotuse AC outputin damp areas if movementis confined or if there is a danger of falling e Use AC output ONLY if required for the welding process output is required use remote output control if present on unit Disconnect input power stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground termina In disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conductor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Donotuse worn damaged undersized or poorly spliced cables Do not drape cables over your body This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols
7. Defective control cable or gun coil Defective 600 0012 P C board Defective 600 0011 P C board Unit Overheated Defective thermal switch Blown 25 amp sustaining arc fuse Defective sustaining arc SCR s Defective 600 0010 P C board Defective 600 0012 P C board Defective choke coil Defective 600 0010 P C board 2 Defective time potentiometer Defective 600 0011 P C board 2 Defective display What To Do Check for defective SCR and replace check and replace Replace Replace Repair Replace fuse repair input line Check for reason for fault 2 Check jumper links on primary board for proper voltage Replace Replace Replace Replace Repair broken leads on connection Replace Check and replace fuse Replace Repair short in cable replace gun coil Replace Replace Allow unit to cool then reduce weld rate to prevent reoccurrence Check and replace Check and replace fuse Replace bad part s Replace Replace Check and Replace Check and Repair Replace Replace Replace Replace PAGE 16 MANUFACTURED BY PROSE WELD MADE IN THE U S A
8. Once the set up has been approved production may be started It is a good idea to test two or three studs every half hour to assure that the set up has not changed This can be accomplished by bending several studs to a 15 degree angle from weld posi tion If failure does not occur the welds should be consid ered good It is not necessary to straighten a stud that is bent Testing should be carried out at the beginning of each day after any change in operator or if the set up is changed in any way PLUNGE POLARITY 1 8 1 4 STRAIGHT 1 8 1 4 STRAIGHT 1 8 1 4 STRAIGHT 1 8 14 STRAIGHT 1 4 3 8 STRAIGHT 1 4 3 8 STRAIGHT PRO WELD ARC 3000 8 A A Figure 5 Control Unit Front View 9 0 PARTS LIST ITEM DESCRIPTION PART NUMBER 1 Switch 104 0014 2 On Off Operator 104 0016 2 N O Contact 104 0017 2 N C Contact 104 0018 3 Power Light Green Neon 102 0087 4 Knob 102 0060 4 20k Potentiometer 111 0012 5 Red LED 108 0028 6 Panel Meter 103 0003 7 Green LED 108 0029 8 Amber LED 108 0030 9 Positive Output Terminal 102 0058 10 4 Pole Panel Mounted Connector 107 0001 PAGE 8 WELD ARC 3000 Figure 6 Control Unit Rear 9 0 PARTS LIST ITEM DESCRIPTION PART NUMBER 12 Fan Motor 102 0068 13 Fan Blade 102 0069 PAGE 9 3000 Figure 7 Control Unit 9 0 PARTS LIST ITEM DESCRIPTION PART NUMBER 14 Start Contactor 113 0012 14 Interlock Contact 113 0013 15 Control Transfor
9. covers and guards closed and securely in place RADIATION can cause interference High frequency H F can interfere with radio navigation safety services computers and communications equipment 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 ARC WELDING can cause interference Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment Such as robots Be sure all equipment in the welding area is electromagnetically compatible Toreduce 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 elec tronic equioment Be sure this welding machina 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
10. 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 materi als furnished where such cost are not expressly authorized in writing The manufacturer does not warrant any parts or acces sories 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 specifica tions to the manufacturer s 3 0 UNPACKING YOUR UNIT Upon receipt of your unit place it as close as possible to the point of installation before unpacking it Once the unit is un packed it is recommended that you inspect it for any physi cal damage that may have occurred in shipping PAGE 1 ARC 3000 Your unit has been completely assembled and inspected at the fa
11. 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 PAGE 5 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 h
12. PRO HELD INTERNATIONAL ARC 3000 OPERATION MAINTENANCE MANUAL WELD 1 0 2 0 3 0 4 0 4 1 4 2 5 0 6 0 7 0 8 0 8 1 8 2 9 0 10 0 11 0 JS Un WN E INTERNATIONAL A 3 TABLE OF CONTENTS PAGE INTRODUCTION 1 WARRANTY io 1 UNPACKING YOUR 71 1 SUGGESTED SAFETY PRECAUTIONS 1 PERSONAL SAFETY PRECAUTIONG 1 POWER SUPPLY SAFETY PRECAUTIONS 2 GENERAL DESCRIPTION e eee e o 2 ELECTRICAL INPUT REQUIREMENT 2 CONTROL PANEL DESCRIPTION eeeessse 4 WELD GUN SETUP 5 PLUNGELENG TH 5 CHECKING 1 11 6 PROCEDURES FOR WELDING H A STUDS 7 PARTS IST de RE TROUBLE 8 16 LIST FIGURES JUMPER LINK 3 CONTROL PANEL 11 4 STANDARD GUN 1 11 essssessssss 5 FUSEBEOCK a 6 CONTROL UNIT FRONT erret 00500 8 CONTROL UNIT REAR eere eene en 4 0 01 7 9 CONTROL UNIT SIDE 10 RECTIFIER WELD BRIDGE ASSY 11 PRINTED CIRCUIT BOARD ENCLOSURE 12 GUN TIMER CONTROL 7 13 MONITOR PCB eo 14 C
13. URRENT CONTROL PCB eee eene 15 PRO WELD INTERNATIONAL ARC 3000 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING EE 1 1 Symbol Usage Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols A Marks a special safety message IF Means Note not safety related A 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 NO TAG Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away 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 Do not touch live electrical parts
14. and related instructions below for necessary actions to avoid the hazards e Ifearth grounding ofthe workpiece is required ground it directly with separate cable do not use work clamp or work cable Donottouch electrode if you are in contact with the work ground or another electrode from a different machine Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical insulate work clamp when not connected to workpiace to prevent contact with any metal object 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 Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts Welding produces fumes and gases Breathing men fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the furnes If inside ventilate tha area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacture
15. c fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures ARC 3000 Keep cables 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 opera tor as practical 5 Connect work clamp to workpiece as close ta the weld possible About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended WELD INTERNATIONAL 1 0 INTRODUCTION Your new stud welding equipment has been carefully con structed using the finest components and material available Used properly this equipment will give you many years of profitable efficient service The system incorporates the latest in engineering advances for complete reliable end welding of mild steel stainless steel and aluminum fasteners A careful study of this manual will enable you to understand how the welder operates to insure proper performance under all conditions 2 0 WARRANTY The electrical and mechanical components of the stud welder are thoroughly performance inspected prior to assem bly in the welder The assembled welder is completely per formance checked The welder is delivered to you in func tional electro mechanical condition All parts used in the assembly of the welder and its accessories are fully warranted for
16. ctory Upon receipt the unit must be hooked up to the recommended incoming power before welding Place the unit in a large enough area to provide adequate ventilation Do not restrict the air flow around the front lou vers or from the fan at the rear of the unit Do not allow wa ter to enter the unit in any way 4 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 recommenda tion to ANSI 749 1 Safety in Welding and Cutting and to AWG Publication A6 1 66 Recommended Safe Practices for Gas Shielded Arc Welding 4 1 Personal Safety Precautions 1 Always treat electricity with respect Under open circuit conditions the welding machines output voltage may be dan gerous 2 Don t work on live circuits or conductors Disconnect the main power before checking the machine or performing any maintenance or repair operations 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 In spect all cables frequently for insulation fa
17. ere is any question about the type of electrical system available at the installation site or how proper connections to the welding power source are to be made The ARC 3000 should be operated from a separate fused or circuit breaker protected circuit Install three primary leads plus one ground wire see tables for proper wire and fuse sizes through the inlet hole in the rear of the unit using proper strain relief The primary cables connect to the terminals L or line The fourth lead ground connection should be fastened to the welder from the ground bolt The other end of the ground lead or cable should be attached to a suitable ground such as a water pipe ground rod etc This unit is equipped with input voltage jumper links either installed or in a bag on the jumper link board to allow opera tion from different line voltages If installed the jumper links are positioned for the highest voltage stated on the nameplate or on the input data label In either case the jumper links should always be checked to see if they are properly positioned for the voltage being used Open the access door located on the lower portion of the rear panel to expose the jumper link board If necessary reposition the jumper links to match the line voltage being used PAGE 2 INTERNATIONAL A e 3 0 0 0 kalao o lain aoo RARA o o 123456 123456 123456 PN PR _ olagdooo 1 23456 123456 123456
18. ilures 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 8 Don t weld on containers which have held combustible or flammable materials or on materials which give off flamma ble or toxic vapors when heated WELD INTERNATIONAL 9 Be sure to provide proper ventilation when welding in a con fined 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 dangers of ultraviolet light to their eyes 4 2 Power Supply Safety Precautions 1 Always connect the frame to the power supply to ground in accordance with the National Electric Code and the manufac turer s recommendation 2 Installation servicing or trouble shooting should be done by qualified personnel trained to work on this type of equipment 3 Before servicing this piece of equipment turn off the discon nect switch at the fuse box 4 When in operation all the covers must be on the equipment 5 0 GENERAL DESCRIPTION THE PROCESS Stud welding is a time saving tool which semi automatically arc welds the FULL CROSS SECTION of a weld stud to the base material in a fraction of a second and develops s
19. mer 230 460 575 60Hz 105 0015 16 Shunt 102 0065 17 Choke Coil 105 0016 18 Main Transformer 230 460 575 60Hz 105 0021 PAGE 10 3000 Figure 8 RECTIFIER SCR ASSEMBLY SIDE AND TOP VIEW 9 0 PARTS LIST ITEM DESCRIPTION PART NUMBER 19 Weld SCR 108 0021 20 Thermostat N O 102 0032 21 Support Arc Module 600 0014 22 SCR Clamp 102 0066 PAGE 11 INTERNATIONAL A 3 0 0 0 9 0 PARTS LIST ITEM DESCRIPTION PART NUMBER 23 Timer Control P C Board 600 0010 24 Monitor P C Board 600 0011 25 Current Control P C Board 600 0012 26 2 ohm 50 watt Resistor 112 0003 27 25 ohm 50 watt Resistor 112 0044 28 Capacitor 106 0024 29 Fuse Block 104 0015 PAGE 12 ERAT ARC 3000 INTERNATIONAL PRO Ri25 110 109 1131
20. olding 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 WELD INTERNATIONAL 8 2 Checking Gun Lift To measure lift turn the stud welding unit on and set the timer to maximum time Set the weld set up switch to weld 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 obser vation or simple measurement against a static reference point i e the ferrule properly seated in the ferrule grip Recommended Lift Settings St
21. ool and foot protection 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 causa 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 Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch fer fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Donot weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e 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 Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in u
22. r for eign materials These materials are contaminants to any welding process especially stud welding due to the short duration of the weld cycle 2 Structural Ground It is always recommended that the welding ground be attached to a spot on a beam that has been ground clean Poor or inadequate ground connections can result in a loss of weld current and there fore affect weld quality 3 Power Requirement for Operating Power Source Consult either the manufacturer or manual for the recommended fusing primary wire size and primary wire length for the power source to be used Inadequate primary power or incorrect wire size or length can contribute to a reduction in weld current WELD TIME WELD CURRENT AMPS 20 40 410 550 30 45 620 830 45 60 855 1045 60 80 1120 1420 80 1 6 1400 1700 1 0 1 2 1648 2020 PAGE 7 ARC 3000 4 Weld Settings Exact weld settings cannot be given because no two jobs are the same Actual settings will depend upon job site condi tions Listed below are approximate settings minimum and maximum Most jobs will fall within these settings NOTE The wide range of weld time on 3 4 studs is appro priate because of the wide range of applications including the weld thru deck possibilities 5 Testing of Welded Studs At least two studs should be bent in any direction to a 30 de gree angle from weld position using a hammer If a failure occurs Re adjust settings and repeat test
23. r s instructions for metals consumables coatings cleaners and degreasers Work in confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe 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 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 furnes if welded INTERNATIONAL Arc rays fromthe welding process produce intense visible and invisible ultraviolet and infrared rays that can bum eyes and skin Sparks fly off from the weld Wearawelding helmet fitted with a proper shade offilter to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Useprotective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material leather and w
24. se e Wear oil free protective garments such as leather gloves heevy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes Welding chipping wire brushing and grinding cause sparks and flying metal welds they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet ARC 3000 BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch e Pacemaker wearers keep away 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 Wear approved ear protection if noise level is high Shielding cylinders contain gas under high pressure damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs Install cylinders in an upright position by sec
25. shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 INTERNATIONAL 1 5 EMF Info Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic 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 power frequency electric and magnetic fields is 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 electromagneti
26. ts either the weld time or weld current that is to be displayed on the digital meter WELD TIME ADJUSTMENT Select SETUP TIME and adjust the time control knob until the digital meter displays the desired time Return setup switch to WELD before attempting to weld The weld time is WELD CURRENT ADJUSTMENT Select SETUP CURRENT and adjust the current control knob until the digital meter displays the desired current Re turn setup switch to WELD before attempting to weld Weld current is adjustable from 300 to 3000 amps DIGITAL PANEL METERS Displays weld time or weld current After a stud weld the digital meter will automatically display the actual weld parameters The meter will automatically re set and display the time or current for each weld DECK WELD SWITCH This switch should only be in the position when weld ing the stud through metal decking With this circuit on the weld current is kept on for an extended period even though the weld time has ended TRIGGER LED INDICATOR The trigger LED on indicates a complete circuit to the unit through the gun control cables and gun switch This LED will turn when the gun trigger is pressed GUN FAULT THERMAL LED INDICATOR The gun fault LED on indicates either the internal tempera ture in the main transformer has reached its maximum or there is a shorted gun solenoid or a shorted control cable In either case the LED will stay
27. ud Base Dia Lift Setting Less than 1 2 1 16 1 27 through 3 4 2 32 Greater than 3 4 7 64 When it does become necessary to adjust lift you do so by remov ing the rear cap from the gun This will expose the rear coil yoke assembly the set screw and the lift adjusting screw Loosen the set screw to avoid damaging the threads of the lift adjusting screw To increase lift turn the lift adjusting screw out counter clock wise To decrease lift turn the lift adjusting screw in clockwise Once the lift has been set tighten the set screw and replace the rear cap ARC 3000 1 AMP 1 AMP 1 AMP 1 AMP 1 AMP 1 AMP 1 AMP 5 AMP CERAMIC 25 AMP SLO BLO 25 AMP SLO BLO 25 AMP SLO BLO Figure 4 FUSE BLOCK Dual gun version shown PAGE 6 PRO zc WELD INTERNATIONAL 9 0 Procedures for Stud Welding Shear Connectors amp Headed Anchors In order to achieve results in any shear connector or headed anchor weld it is imperative that the following procedures be followed 1 Top Flange of Beam The top flange of all beams or plates to be welded should be free of paint excessive rust or mill scale dirt moisture and all othe
28. uperior strength over normal arc welding procedures Since the ARC 3000 stud welding system provides the proper arc length and allows you to select the proper arc time and welding current the variables that affect weld quality are mini mized THE UNIT The ARC 3000 is a fully regulated stud welding power supply that is available in a single or dual gun version Both versions have the constant output feature that allows the unit to be used as a power source that can operate external stud welding con trol units An added feature in the ARC 3000 is the ability to dial in the desired weld time and weld current before even making a weld By selecting the setup mode the weld time and current can be adjusted and displayed on the front panel s digi tal meters ARC 3000 A specially designed electronic gun control circuit has been incorporated in this system If a fault condition occurs due to a shorted gun solenoid or a faulty control cable the circuit will prevent gun triggering and eliminate damage to printed circuit boards The ARC 3000 system is capable of welding studs from 1 4 to 1 1 4 diameter with precision and repeatability 6 0 ELECTRICAL INPUT REQUIREMENT This welding power source is designed to be operated from three phase 60 Hertz AC power supply which has a line volt age rating that corresponds with one of the electrical input volt age shown on the nameplate or input data label Consult the local electric utility if th
29. uring to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a qas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards PRO WELD INTERNATIONAL 1 3 Additional en for Operation and Maintenance han e BH Do not install or hm unit on over or near combustible surfaces Do not install unit near flammables e Donot overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to and support unit Ifusinglift forks to move unit be sure forks long enoughto extend beyond opposite side of unit OVERUSE can cause OVERHEATING
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