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1. 8 90 01 53 N s 90 10 2060 2089 5 5 tocol 18 2 roca J 01 N e wo eoo 2 gogo 1 0 61 del J rey B voso 5 a 02 e 1 m 1 oO ZEH a 9 a a S peaj 1 152 _ 8 EO 12 J oe Z0EdO ted 1 x N vOED weed boedo reu 20801 8 8 62 29 10869 5 lt 5 lle 3 allel s lglg 8 Sjel 5 8 5062 I D326 I D327 Figure 11 CURRENT CONTROL P C BOARD P N 600 0012 PAGE 12 MANUFACTURED BY PRO WELD MADE IN THE U S A2. Figure 5 FUSE BLOCK PAGE 6 PRO WELD INTERNATIONAL A R C 1 2 0 0 11 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 PAGE 7 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 potentiometer Blown 5 amp fuse 2 Defective 600 0010 P C board Defective control cable or gun coil Defective 600 0012 P C board Defective 600 0011 P C board Blown 1 amp fuse 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 Open weld cable or bad weld ground connection Defective 600 0010 P C board 2 Defective t
3. INTERNATIONAL ITEM 17 17 18 19 21 22 23 24 25 ARC 1200 Ba 4 1 4 Figure 9 CONTROL UNIT SIDE VIEW DESCRIPTION PART NUMBER Norm Open Contact 104 0017 Norm Closed Contact 1040018 M Trans 1200 230 440 575 60HZ 105 0019 Wheels 102 0036 Axel Cap 102 0027 SCR 108 0057 SCR Clamp 102 0106 Buss Bar 124 0045 C Trans 3000 60HZ 230 460 575V 105 0015 Shunt 102 0081 Front Caster NOT SHOWN 102 0082 PAGE 10 INTERNATIONAL ARC 1200
4. PAGE 11 D12 V106 VO of Tea t a N e x a 3 HARES eeg 8 EE C107 25105 108 D127 C105 2 _ R153 R126 on ib D124 R127 1 141 E y 9 28 al alz 5 gt Q gt gt N m 5 S amp S V107 Ni S V103 2 oN OFF 5 lo D110 103 cc 111 S oP e g as R137 Q l 102 oP A 5 109 VR101 2 2 oP S g 28888 5 R102 l 105 7 R148 0140 4 C101 F 2 OP 8 C113 5 2 A 106 gt 5 1085 S A 815 OP sS a D N alala ala 1197 55 55 107 133 D121 Figure 10 GUN TIME CONTROL P C BOARD P N 600 0010 1200 INTERNATIONAL
5. WIEILID INTERNATIONAL ARC 1200 9 9 gt lt 9 k massa Ss alk OPERATION MAINTENANCE MANUAL PRO WELD ARC 1200 INTERNATIONAL TABLE OF CONTENTS Section 1 SAFETY PRECAUTIONS PAGE 1 0 INTRODUCTIONN 1 2 0 WARRANIY 1 30 UNPACKING YOUR UNIT 1 40 SUGGESTED SAFETY 1 41 PERSONAL SAFETY PRECAUTIONG 1 42 POWER SUPPLY SAFETY PRECAUTIONSG 2 5 0 GENERAL DESCRIPTION 2 6 0 ELECTRICAL INPUT REQUIREMENIT I 2 7 0 CONTROL PANEL DESCRIPTIONN 3 80 WELD GUN SETUP 3 81 PLUNGE LENG IH 3 82 CHECKING GUN LIFT 4 90 SETTING UP THE POWER SOURCE 5 91 CONNECTIONS AND SETTINGS 5 92 WELD TEST AND INSPECTION 5 10 0 MAINTENANCEKE 6 10 1 WELD CABLES 6 10 2 INTERNAL CLEANING 6 110 TROUBLE SHOOTING 7 12 0 PARTS L
6. Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards 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 elactrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy 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 injure eyes Welding chipping wire brushing and grinding cause sparks and flying metal As welds they can throw off slag e Wear approved safely glasses with side shields even under your welding helmet 1200 Shut off shielding gas supply when not in use Always ventilate confined spaces or use approved air supplied respirator HOT Do not touch parts bare handed Allow cooling period before working qun or torch can cause severe burns Pacemaker wearers keep away Wearers should consult their doctor before going near arc weldin
7. 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 Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy 02269 ols for installation and Maintenance ARC 1200 MOVING PARTS c cause indian Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place RADIATION can cause interference High frequency can interfere with radio navigation safety services computers and communications equipment Have only qualified persons familiar with electronic equipment perform this installation e 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 WELDING can cause interference Electromagnetic energy can interfere with sensitive electronic equip
8. 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 body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a 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 electromagnetic fields when welding or cutting To reduce magnetic fields the workplace use the following procedures ARC 1200 1 Keep cables close together by twisting or taping them 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 to the weld as 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 incorpor
9. START button PAGE 5 ARC 1200 Table 9 1 Approximate Settings Stud Base Weld Weld Minimum Plate Inches mm Seconds Ampers Inches mm 1 4 6 4 0 20 425 0 048 1 22 516 7 9 0 25 500 0 060 1 52 3 8 9 5 0 33 550 0 075 1 91 716 11 1 0 40 675 0 089 2 26 12 12 7 0 55 800 0 120 3 05 5 8 15 9 0 67 1200 0 148 3 76 9 2 Weld Test and Inspection Testing of weld quality beyond visual inspection varies with stud characteristics Refer to AWS American Welding Society Structure Welding code AWS D 1Rev 1 76 Welding procedures are covered in Sections 4 28 and 4 29 Weld test and inspection is covered in Section 4 30 para graphs 1 through 4 American Welding Society inc 2501 N W 7th Street Miami Fla 33125 STUD HANG UP Adjust foot to insure the stud is centered in the ferrule GOOD STUD WELD A good full fillet COLD WELD Increase weld current and or weld time HOT WELD Reduce weld current and or weld time figure 4 WELD INSPECTION PRO WELD INTERNATIONAL A Bend Test Repeatedly bend the stud away from its axis until failure occurs B Torque Test Threaded Studs Twist the stud to point of failure Apply a twisting tensile load by using a collar washer and nut C Test Results In an acceptable weld failure will occur in the stud material or tear out of a thin base plate Failure in the weld requires adjust ment of pocedure weld time weld current or gun setup
10. 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 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 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 there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Disconnect input power or stop engine before installing 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 termin
11. 10 0 MAINTENANCE CAUTION Electric Shock Can Kill e Do not touch live electrical parts Shut down welding power source and disconnect input power before inspecting maintaining or servicing Lockout tagging procedures consist of padlocking line discon nect switch in the open position removing fuses from fuse box or shutting off and red tagging circuit breaker or other discon necting device MOVING PARTS can cause serious injury Keep away from moving parts HOT SURFACES can cause severe burns Allow cooling period before servicing ARC 1200 CAUTION Read and follow the safety information at the begining of this section before proceding 10 1 WELD CABLES Every three months inspect cables for breaks in insulation Repair or replace cables if insulation breaks are present Clean and tighten connections at each inspection 10 2 INTERNAL CLEANING Every six months blow or vacuum dust and dirt from th ein side fo the welding power source Remove the outer enclo sure and use a clean dry airstream or vacuum suction for the cleaning operation If dusty or dirty conditions are pres ent clean the unit monthly 1 AMP 1 AMP 1 AMP 1 AMP 1 AMP 5 AMP 25 AMP SLO BLO 25 AMP SLO BLO 25 AMP SLO BLO
12. IST 8 9 10 LIST OF FIGURES 1 JUMPER LINK ARRANGEMENII 2 2 CONTROL PANEL FRONI I 3 3 STANDARD GUN SET UP 4 4 WELD INSPECTION 5 5 6 6 CONTROL PANEL S 7 PCB ENCLOSURE 8 8 CONTROL UNIT SIDE VIEWA 9 9 CONTROL UNIT SIDE VIEW 10 10 GUN TIME CONTROL PC 11 11 CURRENT CONTROL PC B8 12 PRO WELD INTERNATIONAL ARC 1200 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING eee hazards with this procedure The possible hazards are shown in the adjoining symbols A Marks a special safety message 7 Means Note not safety related 19 Arc Welding Hazards 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
13. NATIONAL Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can bum eyes and skin Sparks fly off from the weld Wear a welding helmet fitted with a proper shade offilter to protect your face and eyes when welding or watching see ANSI 249 1 and 287 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective 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 wool and foot protection 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 cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the is safe before doing any welding va 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 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 Watch for fire and keep a fire extinguisher nearby
14. ONAL PRO When it does become necessary to adjust lift you do so by removing 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 9 0 SETTING UP THE POWER SOURCE 9 1 Connections and settings CAUTION Turn the power off before making connections a Connect the male end of the GROUND CABLE to the posi tive GROUND terminal of the power supply and secure the clamp to the base plate Make sure both connections are tight and the base metal is free of heavy paint or rust at the ground connection points b Connect the male end of the COMBINATION CABLE SET to the negative GUN terminal of the power supply c Plug in the control cable portion of the COMBINATION CABLE SET into the control cable receptacle in the front of the power supply d Position the Time Range switch in either A or B depend ing on the required weld time e Set the Time adjustment required for the particular stud size see table 9 1 f Set the Current adjustment to the current setting for the par ticular stud size see table 9 1 g Turn on the power supply by depressing the
15. al in disconnect box or that cord plug is connected to 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 and related instructions below for necessary actions to avoid the hazards 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 workpiece to prevent contact with any metal object not connect more than one electrode work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverter
16. ates 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 ac cessories are fully warranted for a period of 1 YEAR from the date of delivery In addition the welding capacitors are war ranted for a period of 1 YEAR from the date of delivery The printed circuit boards used in all proweld equipment are war ranted 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 acces sories against failures resulting from
17. 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 adjust the lift height 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 CY CLE 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 t
18. g gouging or spot welding operations Noise fram some processes equipment can damage hearing Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If 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 securing 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 gas cylinder Never allow a welding electrode to touch any cylinder Never weld 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 in 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 Additional Sy 7 FIRE OR EXPLOSION hazard e Do not install place unit
19. he 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 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 8 2 Checking Gun Lift To measure 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 ref erence point i e the ferrule properly seated in the ferrule grip Recommended Lift Settings Stud Base Dia Lift Setting Less than 1 2 1 16 1 2 through 3 4 3 32 Greater than 3 4 7 64 4 INTERNATI
20. ime potentiometer 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 Check and replace fuse Check and replace fuse Replace bad part s Replace Replace Check and Replace Check and Repair Replace Replace 1200 Figure 6 FRONT PANEL Figure 7 PCB ENCLOSURE 12 0 PARTS LIST ITEM DESCRIPTION PART NUMBER 1 Knob 102 0060 2 Hi Low Switch 104 0014 3 Red LED 108 0028 4 Green Neon Light 102 0087 5 Start Stop Operator 104 0016 Open Closed Contacts Needed for Operator 6 Arc 1200 Decal 122 0020 7 SCR Isolated 25A 400V 108 0042 8 PCB Current Control 600 0012 9 Choke Coil TR1600 450 105 0004 10 PCB Time CTR 600 0010 11 Circuit Board Hold Down 102 0098 9 INTERNATIONAL ARC 1200 ITEM 12 12 13 15 15 16 Figure 8 CONTROL UNIT SIDE VIEW DESCRIPTION 14 Fan Blade 1 2 Hub for Fan Blade Fuse Holder Fuse 6A 250V Contactor Interloc Motor 1 8 HP PART NUMBER 102 0083 102 0084 104 0033 120 0008 113 0019 113 0020 102 0085
21. itions 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 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 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 PRO WELD INTERNATIONAL 9 Be sure to provide 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 un aware of the dangers of ultraviolet light to their eyes 4 2 Power Supply Safety Preca
22. k on If there is a thermal overload the LED will remain on until the temperature on the trans former comes down to a safe operating temperature 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 WELD INTERNATIONAL F Plunge Length Fenula Grip ARC 1200 Leg Adj Screw Figure 3 Standard Gun Set up 3 The plunge length is the amount of the stud exposed be yond the ferrule during initial set up Set the plunge by loos
23. ment such as computers and computer driven equipment such as robots Be sure all equipment 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 fioor Locate welding operation 100 meters from any sensitive elec tronic equioment Be sure this welding machine is installed and grounded according to this manual f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line fitters or shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet 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 MSW 183 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard 287 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 In Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro
24. 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 physical damage that may have occurred in shipping PAGE 1 ARC 1200 Your unit has been completely assembled and inspected at the factory 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 ven tilation Do not restrict the air flow around the front louvers or from the fan at the rear of the unit Do not allow water 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 Z49 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 cond
25. oltage 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 posi tioned 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 reposi tion the jumper links to match the line voltage being used see Figure 6 1 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 TIME RANGE SWITCH This switch is used to select either the A or time range settings on the time adjustment knob PAGE 3 THERMAL GUN FAULT LED INDICATOR The thermal gun fault LED indicates either the internal temperature in the main transformer has reached its maxi mum or there is a shorted gun solenoid or a shorted control cable In either case the LED will stay on and lockout the gun from triggering 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 bac
26. over near combustible surfaces Do not install unit near flammables Donot overload building wiring be sure power supply system is property 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 Use equipment of adequate capacity to lift and support unit fusing forks to move unit be sure forks long enough to extend beyond opposite side of unit _OVERUSE can cause OVERHEATING 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 cause injury e Keep away from moving parts Keep away from pinch points such as drive rolls WELDING WIRE can cause injury not press gun trigger until instructed to do not point gun toward any part of the body other people or any metal when threading welding wire Safaty in Weiding and Cutting ANSI Standard 29 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 1910 from Superinten dent of Documents U S Government Printing Office
27. power source is designed to be operated from three phase 60 Hertz AC power supply which has a line voltage rating that corresponds with one of the electrical in put voltage shown on the nameplate or input data label Con sult the local electric utility if there 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 power unit should be operated from a seperately fused or circuit breaker protected circuit The primary input voltage connection terminal board is lo cated behind the access door on the rear panel Install three primary leads plus one ground wire see FIG 1 for proper wire and fuse sizes through the inlet hole in the rear of the unit The primary cables connect to terminals labeled L or LINE A FOURTH LEAD GROUND CONNECTION SHOULD BE FASTENED TO THE TERMINAL LABELED GND The other end of the ground lead or cable should be attached to a suitable ground such as a water pipe ground rod ect Use whatever grounding means is acceptable to the local PAGE 2 PRO WELD INTERNATIONAL ARC 1200 Figure 2 CONTROL PANEL FRONT CAUTION The stud labeled GND is connected to the unit chassis and is for grounding purposes only Do not connect a wire from the terminal labeled GND to one of the three phase line termi nals as this may result in hot power unit chassis This unit is equipped with input v
28. s Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES oan bo hazardous Welding produces fumes and gases Breathing fumes and gases be hazardous to your health Keep your head out of the fumes Do not breathe the fumes if inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work 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 coated metals such as galvanized lead cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an ait supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded INTER
29. utions 1 Always connect the frame to the power supply to ground in accordance with the National Electrical Code and the manufacturer s recommendations 2 Installation servicing or trouble shooting should be done by qualified personnel trained to work on this type of equip ment 3 Before servicing this piece of equipment turn off the dis connect switch at the fuse box 4 When in operation all the covers must be on the equip ment 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 superior strength over normal arc welding procedures Since the ARC 1200 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 minimized THE UNIT The ARC 1200 is a compact and portable stud welding power supply capable of welding studs thru 5 8 diameter weld base The fully regulated power supply which operates on three phase power produces a smooth stable welding arc Both the weld time and weld current are infinitely adjustable for preciseness and repeatability ARC 1200 PRIMARY WIRE DELAY TYPE FUSE SIZE AWG GND SIZE IN AMPS 230V 4 8 120 460V 10 10 60 S75V 10 10 50 575 VOLT Figure 1 Jumper Link Arrangement 6 0 ELECTRICAL INPUT REQUIREMENT This welding
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