Studhorse1200DM manual US&CE 2009-1 - Red-D
Contents
1. When testing a live unit use the one hand method Do not put both hands inside of the unit Keep one hand free Disconnect input power conductors from de energized supply line before moving a welding power source Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Turn OFF welding power source before servicing unless the procedure specifically requires an energized unit Never touch the energized stud or gun before discharging the stud to ground Never use the power source to provide heat for thawing frozen pipes ARC RAYS and EYE PROTECTION Arc rays can injure eyes and burn skin Arc flashes are painful Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or while observing open arc welding Use protective clothing specifically intended for work with welding equipment It should be made of durable flame resistant material to provide ample protection from the arc rays Protect other nearby workers with suitable non flammable screening Caution other workers not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 1 5 FUMES and OXYGEN DEPLETION Only weld in areas or rooms where adequate ventilation weld gases is possible and where there are not fire smoke or explosion hazards 1 When working in a confined spac2. 7 7 7 ja 8 6 Chassis Plate Drawing 2 w Part References C x 2 o xD 7S i E A FA 9 SAN V y A N NIX 8 7 Inductor Plate Drawing w Part References ARCON WELDING LLC 1 3 SALISBURY MD U S A 2 8 4 j 11 15 ee OE FILE KEY 4 0 6 RESP DEPT BUSHINGS GE 5 1 DFTR J ARMIGER 08 Oct 00 UNITS INCHES DRAWING NO 6 2 8 CHKD SCALE 0 600 04 iQ ae RE APPD LANG ENGLISH REV 2 SHEET OF 3 2 6 STUD WELDER REPLACEMENT PARTS LIST PAR
3. The Power On indicator light will show that input power is being supplied to the machine 4 3 2 Digital Meter on The Studhorse 1000DM amp 1200DM models The digital current and timer meter displays current when the push button toggle switch is pushed once and displays time when pushed in again After switching on the input power to the machine the four digit display shows the operational mode PA The display shows the actual Current for three seconds after each Stud has been welded The Current setting is displayed as and actual Current is displayed as X XXX If display flashes the machine has exceeded its temperature limits Wait until the machine has cooled may take up to 4 minutes indicated by the the display no longer flashing and then resume welding 14 4 3 3 Setting the Welding Current and Time Pressing the push button switch on the front panel toggles the display presentation between Current and Time There are separate potentiometer controls for setting the Current and the Time When the current value is set and a stud is welded the actual current delivered measured value is displayed for 3 seconds after completion of the stud Thereafter the set value is displayed again The measured current may fluctuate up to 5 dependent on the angle of the stud and the surface on which the weld is performed Typical variations from stud to stud may be a low as 196 The Stud Time can be set from 0 05 seco
4. probably the toughest welders on the planet STUDHORSE 1200DM STUDHORSE 1000DM P N 101201 1200 Amp Drawn Arc Stud Welder P N 101001 1000 Amp Drawn Arc Stud Welder OPERATING MANUAL REVISED DECEMBER 2009 2203 Northwood Drive Unit 10 Salisbury MD 21801 Tel 410 572 6000 Fax 410 572 6027 sales arconweld com www arconweld com Declaration of Conformity Manufacturer s Name Manufacturer s Address Declares that the product Product Name Model Number Conforms to the following standards Underwriters Laboratories Standard Safety Degree of Enclosure Protection ARCON Welding Equipment LLC 2203 Northwood Drive Unit 10 Salisbury Maryland 21801 USA Studhorse 1200DM Studhorse 1000DM 101201 xxx 101001 xxx UL551 EN 60974 1 2002 IP 24 in accordance with ISO 60529 This product is in conformity with the requirements of the Low Voltage Directive 73 23 EEC and Machinery directive 89 392 EEC 91 368 EEC 93C 133 04 93 68 EEC Compliance Certified by Technical Contact For further details please contact the factory Goran Hedberg Design Engineer Mike Bell Product Engineering ARCON Welding Equipment LLC 2203 Northwood Drive Unit 10 Salisbury Maryland 21801 Fax 410 572 6027 Email mike arconweld com ARCON Welding Equipment LLC 2203 Northwood Drive 10 Salisbury Maryland 21801 USA Tel 410 572 6000 Toll Free 888 512 7266 Fax 410 572 6027 Email sales arconweld com service
5. circuitry and a radio noise suppression module The AC voltage is connected to a step down transformer to power the welder The AC welding voltage 15 first rectified to create a DC welding current The control logic measures the welding voltage and welding current It also makes the inverter create the suitable welding characteristics The auxiliary transformer steps down the input voltage to 48V center tapped This transformer powers the cooling fan and the control logic 23 SAFETY STANDARDS The Studhorse 1200DM amp Studhorse 1000DM are designed and manufactured to comply with the following safety standards Underwriters Laboratories Standard UL551 Safety EN 60974 1 Degree of Enclosure Protection IP 24 in accordance with ISO 60529 e Protection against full penetration of solid foreign objects of 12 5mm diameter and larger e Protection against harmful effects from splashing water against the enclosure from any direction 3 INSTALLATION WARNING e Only qualified personnel should perform this installation e Turn the input power off at the disconnect switch or fuse box before working on The Studhorse Do not touch electrically hot parts 11 This section provides detailed instructions for the proper installation of The Studhorse lt is recommended that these instructions be followed carefully to allow for the best possible operating environment 31 Handling and Unpacking the Welder Since The Studhorse 1200DM amp Stu
6. and greyish Weld power too low Increase currant and or collar time Length too long Ceramic ferrule is moist Dry out ferrules in oven 4 Collar off centre Effect of arc blow See table 8 Uindercut Ceramic ferrule incorrectly Check centring centred 19 5 1 Visually Inspecting Welded Studs continued Probable cause Collar height reduced bright Weld power too high Reduce current and or time with large lateral projections Length after weld too short Plunge rate too high Adjust plunge and or gun damper Fracture examination Probable cause Tearing of parent metal Correct parameters Fracture above collar after Correct parameters sufficient deformation Tearing within the weld Weld power too low Increase current and or time High porosity Check chemical composition Metal not suitable for stud welding 20 5 1 Visually Inspecting Welded Studs continued Corrective actions Fracture in Carbon content of parent Check parent metal metal too high Greyish fracture surface Increase weld time without sufficient deformation Parent metal not suitable Preheating can be necessary Fracture of weld Flux content is too high Check flux quantity Bright appearance Weld time too low Increase weld time Lamellar tearing of parent Non metallic inclusions in parent metal Parent
7. arconweld com www arconweld com Studhorse Operations and Service Manual TABLE OF CONTENTS GENERAL INFORMATION User Responsibility Limited Warranty Safety Standards Corrosion Protection 1 SAFETY 1 1 Safety Symbols 1 2 Safety Precautions 1 3 Electric Shock Can Injure or Kill 1 4 Arc Rays Can Injure Eyes and Burn Skin 1 5 Fumes and Oxygen Depletion Can Be Dangerous to Your Health 1 6 Welding Sparks Can Cause Fire and Explosion 1 7 Electric and Magnetic Fields May be Dangerous 1 8 Protect Yourself and Others 2 PRODUCT DESCRIPTION amp INFORMATION 2 1 Introduction to The Studhorse 1200 DM and 1000DM 2 2 Product Specifications 2 3 Safety Standards 3 INSTALLATION 3 1 Handling and Unpacking the Welder 3 2 Selecting a Location 3 3 Selecting Suitable Supply Cables 3 4 Connecting Input Power 3 5 Fuse and Circuit Breaker Ratings 3 6 Output Connections and Stud Gun Selection 3 7 Stud Guns 4 OPERATION 4 1 General Description 4 2 Design Features 4 3 Operational Controls and Settings 4 3 1 Circuit Breaker Power on Off 4 3 2 Digital Meter on The Studhorse 1200DM 1000DM Models 4 3 3 Setting the Welding Current amp Time 4 3 4 Process for various Stud Welding Positions 4 3 5 Process Control Selection Figure 4 1 4 4 Welding Operation 4 4 1 Begin welding utilizing Factory suggested Weld Setpoints 4 4 2 Digital Timer and Setting Operation for the Studhorse 1200DM 1000DM 4 4 3 Discharging the Current after a dry fire the Stu
8. in your Studhorse power source Main Transformer If overheating occurs wait 1 minute before restarting Main Inductor If overheating occurs wait 7 8 minutes before restarting Output Capacitor The Output Capacitor may overheat and shut down the welder If this occurs wait 10 minutes before restarting The temperature sensor will protect the output capacitor Input Capacitor Should one phase be lost when welding with three phase input power current to the Input Capacitor could increase causing it to potentially overheat or be destroyed Wait 10 minutes before restarting the welder Fan Motor oome operation with restricted airflow will overheat the fan motor Wait 10 minutes before restarting the welder 18 5 VISUAL INSPECTION 5 1 Visually Inspecting Welded Studs Use this guide to visually inspect welded studs to determine the quality of weld The correct relationship between the Lift Plunge Time and Current is essential in order to obtain good weld results Operators should used this guide to help interpret the appearance of the weld collar Visual examination Corrective actions 1 Collar regular bright and Correct parameters complete Lengths after weld within tolerances 2 Reduced diameter weld insufficient plunge or lift increase plunge check centring of ferrule check lift Length tao long Welding power tao high Reduce current and or time 3 Reduced irregular
9. metal not suitable 21 5 1 Visually Inspecting Welded Studs continued Visual examination us t Corract parameters 1 Regular collar no visual defects 2 Partial weld Weld power too low Polarity incorrect Weld time too high 4 Pores in collar Weld time too long Current too low Oxidation of weld pool n Collar off centra Effect of arc blow LB See table 3 Increase current and or time Correct polarity Reduce time Reduce weld time Increase current Provide suitable shielding qas 22 5 1 Visually Inspecting Welded Studs continued Fracture examination Probable cause Tearing of parent metal Correct parameters Fracture above collar after Correct parameters sufficient deformation e Fracture in HAZ Carbon content of parent Check parent metal metal tao high Parent metal not suitable Lack of penetration Heat input too low Increase heat input Incorrect wald polarity Correct weld polarity 23 6 MAINTENANCE amp REPAIR WARNING Please see Chapter 1 regarding Safety Turn the input power OFF before working on any ARCON stud welder Do not touch electrically live parts or electrode with your skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves Have an electrician install the ARCON s
10. BOARD MAN CONTROL 011520 001_ ASSY INPUT RECTIFIER CF Wa 016411 002 VARISTORFOR CFASSY S88 011610 002 METER DIGITALDISPLAY 010580 001 CONTROLASSY STUD TIME CURRENT 39 101520 001 PC BOARD STUD GUN CONTROL 1 40 _ 35 016010 001 CAPACITOR INPUT 011551 001 INPUT w PTC 42 015101 001 CAPACITOR OUTPUT w PIC 43 016020 001 CAPACITOR OUTPUT 010560 002 OUVER FRONT C C s s s s 010512 002 46 016920 001 RELAY FOR STUD GUN CONTROLBOARD 47 016202 001 RESISTOR SURGE 01504 48 016330 001 CIRCUITBREAKER 50 018401 001 BRACKET MOUNTING FOR CIRCUIT BREAKER 51 016331 001 SPACER FOR CIRCUITBREAKER M 52 016611 001 DIODE CATHODE STUD FOR CAPBOARD 60 016610 001 DIODE ANODE STUD FOR CAP BOARD 61 016627 020 RESISTOR 12 OHM FOR OUTPUT BOARD 63 017102 002 CLAMP KICKSTART CAPACITOR METAL 64 017102 001 CLAMP OUTPUT CAPACITOR e 017102 003 CLAMP INPUT CAPACITOR w PTC BOARD 66 017110 001 BRACKET MOUNTING TRANSFORMER 67 018500 001 JACK OUTPUT DINSE FOR PLASTIC PANEL 68 018500 005 JACK OUTPUT DINSE FOR METAL PANEL 68 018502 001 OUTPUT CAMLOCK FOR PLASTIC PANEL 68 018502 005 ACK OUTPUT CAMLOCK B
11. LACK FOR METAL PNL 68 018502 006 OUTPUT CAMLOCK RED FOR METAL PANEL 68 018501 001 OUTPUT TWECO FOR PLASTIC PANEL 68 018502 007 ACK OUTPUT TWECO FOR METAL PANEL 68 011500 011 CIRCUIT BOARD CAPACITOR ASSY 40V 69 011500 012 CIRCUIT BOARD CAPACITOR ASSY 480 69 018709 101 REMOTE ON REAR PANEL WIRED 73 016002 001 CHASSIS CAPACITORS 011530 001 CIRCUIT BOARD OUTPUT ASSY 76 016201 001 RESISTOR POWER 40 OHM CENTER TAPPED 77 010401 001 CASE BOTTOMS 010410 003 CASE TOP w HANDLES 36 STUD WELDER ACCESSORIES PART ee NUMBER DESCRIPTION a T C 37
12. ON Welding Equipment reserves the right to make engineering and or part changes at any time without notice as improvements in quality or design are made Owners and operators of The Studhorse 1200DM amp Studhorse 1000DM should access the company Web site listed above to keep up to date with offerings applications and technical suggestions SAFETY STANDARDS The Studhorse 1200DM amp Studhorse 1000DM are designed and built to comply with the following safety standards Underwriters Laboratories Standard UL551 Safety EN 60974 1 Degree of Enclosure Protection IP 24 in accordance with ISO 60529 e Protection against full penetration of solid foreign objects of 12 5mm diameter and larger e Protection against harmful effects from splashing water against the enclosure from any direction Please review all safety infomation in Section 1 very carefully before operating the machine This machine is protected against corrosion ARCON s time proven Seahorse manufacturing process protects electrical components prone to failure from corrosion by design and using a compound containing cycloaliphatic epoxides tetramethylen oxide and a cationic photo initiator commonly called conformal coating This protection is incorporated as certain electrical components and printed circuit boards are produced to ensure excellent weathering and superior protection against humidity moisture dust fungus and other contaminants The Seahorse process used in thi
13. PART 101201 D scr APPROVED BY SIGNATURE AT INITIAL RELEASE COMPUTER GENERATED DWG THIS DOCUMENT IS THE PROPERTY OF ARCON WELDING L L C REPRODUCTION OR DISCLOSURE IS FORBIDDEN UNLESS AUTHORIZED BY ARCON 8 3 Front Panel drawing w Part References 1 STU DWELD DIGITAL METER 2 TIME ADJUSTMENT KNOB 5 CURRENT ADJUSTMENT KNOB L TIME CURRENT DISPLAY SWITCH 8 4 Rear Panel Drawing w Part References 1 of 1 8 5 Chassis Plate Drawing 1 w Part References NC K X Lu Lu f 2m OO ns hp sak s 2 roe CD gt C O lt C COD lt T gt lt lt x 8 a V EAE a D IN es lt gt lt O aala m c eS c gt CMM e CO o gt Cro m ES or Li lt misi Gis lt S 9 Luo 2 lt lt x ZZ EL ANAMA KNINNYZ Sr sr ley CO N pe gt 2 N AK N E er N 2 S 7 Js VA W x 4
14. T NUMBER DESCRIPTION REF O 011260 011 TRANSFORMER MAIN w PTC 40V 011260 013 TRANSFORMER MAIN w PTC 480V 1 010440 001 POWER CABLE ASSY 10AWG 12 9FTCE 2 010490 003 CHASSIS MAN 3 010520 002 PANEL REAR METAL 45 46 010511 012 PANEL UPPER REAR PLASTIC 4 010513 001 PANEL LOWER REAR PLASTIC W5 010551 013 PANEL FRONT PRINTED 6 010553 001 AMP INDICATOR L 7 017001 002 KNOB FOR TIME CURRENT CONTROL 8 010601 001 WEATHER FOR CIRCUIT BREAKER 13 011210 001 CHASSIS INDUCTOR 011215 001 ANASSY 5 011216 001 FANBLADE s s 3 011220 002 NDUCTOR OUTEUT 18 011230 001 INDUCTOR MAIN w PIC 19 011241 001 NDUCTOR COMMUTATING FRONT M 20 011251 001 NDUCTOR COMMUTATING REAR 21 011272 001 TRANSFORMER AUXILIARY 40V 23 011272 012 TRANSFORMER AUXILIARY 480V V 23 011300 001 SHUNT CALIBRATED 24 010420 012 ASSY UPPER REAR PANEL 28 019900 002 STRAIN RELE 26 019900 102 NUTFOR STRAINRELEF 27 011401 001 455 DIODE amp HEATSINK Ws 011541 001 455 SCR amp HEATSINK 31 010550 112 JASSY FRONT PANEL I 32 011510 012 PC
15. V 24 30A Time Delay Slo Blow 460V 480V 30A Time Delay Slo Blow Table 2 0 3 6 Output cable connections The standard supplied output connectors on the rear panel are female Cam Lok type Welders may have been supplied with Tweco type or Dinse DIX type if special ordered Certain adapters for connection to welding cables can be supplied as an option Maximum recommended length is 50 feet 2 0 total gun and ground cable 3 7 Stud Guns There are several manufacturers of Stud welding guns A Stud gun is shaped to fit in the hand in the shape of a handgun and is a semi automatic stud welding tool Guns vary in design connection weight capacity and Duty Cycle Only guns suitable for drawn arc Stud welding can be used and are available for Short Cycle Standard Duty and Heavy Duty use The pin configuration of the gun must be compatible with The Studhorse 1200DM and 1000DM Units come standard with a 4 pin panel mounted control connector for the firing gun The pistol grip switch initiates the stud current through the welding cables and at the same time powers the solenoid in the gun so that it retracts Attach the gun cable to the jack on the power supply and attach the ground clamp to the jack on the power supply There is very little to do when unpacking the Stud Welding gun The gun should be complete with all the tools and accessories required for setup adjustment and maintenance Guns should be equippe
16. ctrically charged or hot when The Studhorse is switched on and the gun trigger is depressed Do not touch these hot parts with bare skin or wet clothing before the discharging to ground The electrical charge in live in the gun for approximately 20 seconds after the trigger is pulled on a dry fire Water moisture and human skin are electrical conductors and complete an electrical circuit to ground earth allowing current to easily flow Never weld in wet clothing gloves or footwear Always protect yourself from electricity using dry insulation Never leave an energized machine unattended and always check the condition of cables connections and protective gear Always keep one hand free when testing an energized machine and unplug equipment before cleaning or servicing Please review and follow all safety precautions in this manual before using the equipment 4 4 4 Responding to the 5 Zones Thermal Protection Control The display will begin blinking if any component is overheating The operator must stop welding studs and allow the power source to cool down This may take 3 minutes or more depending on which component is overheated The following components monitor the internal temperature in The Studhorse welder The 5 Zones of termal protection are incorporated to protect the machine from over temperature and extend the useful life of the machine The feature also reduces the risk of costly repairs The following zones are protected
17. d does not weld 4 4 4 Five Zones Thermal Protection Control O1 CO CO COO OO N VISUAL INSPECTION 5 1 Visually inspection welded Studs MAINTENANCE AND REPAIR TROUBLESHOOTING GUIDE ELECTRICAL SPECIFICATIONS amp DIAGRAMS 8 1 The principles of the inverter design Figure 8 1 8 2 Main Circuit Diagram 8 3 Front Panel Drawing with part references 8 4 Rear Panel Drawing with part references 8 5 Chassis Plate Drawing 1 with part references 8 6 Chassis Plate Drawing 2 with part references 8 7 Inductor Plate Drawing with part references PARTS AND ACCESSORIES 9 1 Replacement Parts 9 2 Accessories GENERAL INFORMATION User Responsibility ARCON Welding warrants that The Studhorse 1200DM amp Studhorse 1000DM will perform in accordance with the product description in this manual The Factory Warranty will be null and void should the user attempt to operate The Studhorse after it has malfunctioned Parts that are broken missing or worn must be replaced immediately ARCON Welding Equipment LLC or its Authorized Repair Center will perform warranty Repairs Studhorse or any of its parts must not be altered without the prior written approval of ARCON Welding Equipment LLC Any malfunction resulting from improper use faulty maintenance physical damage unapproved repair or alteration shall be the sole responsibility of the user or owner Any repair to improperly used or abused equipment by ARCON Welding Equi
18. d with the correct chuck ferrule grip and special accessories for each application Operators should consult the Operation Maintenance Manual from the Stud Gun manufacturer for complete instructions for safe operation and maintenance 13 4 OPERATION WARNING PLEASE READ CHAPTER 1 REGARDING SAFETY 41 General Description The Studhorse power source combines time proven technology with modern technology to provide high quality performance The digitally controlled SCR type inverter is very reliable in welding applications and capable of welding full base weld studs in a variety of applications 30 Amp Slo Blow fuses provide protection for 400V and 480V input models 4 2 Design Features The Studhorse power source is designed to be portable and easily transported to provide many benefits No crane or special lifting devices are required to move or maintain the machine The machine provides Constant Power output with Inverter smooth arc incorporating digitally controlled start stop Other features include regulated output step less weld power and time adjustment short circuit protection automatic line voltage protection and 5 zones of thermal protection 4 3 Operational Controls and Settings also refer to Figure 4 1 4 3 1 Circuit Breaker Power On Off The Circuit Breaker serves as the main input power switch and located on the control panel at the rear of the machine Move the switch lever up to the ON position to start the machine
19. dhorse 1000DM machines weigh approximately 90 pounds in the shipping carton no fork lift or crane is necessary to move the machine The shipping carton has built in reinforced handles to enable two people to easily transport the machine Immediately upon receipt of the welder inspect the shipping box for any damage and notify the carrier of such damage before accepting delivery Then inspect The Studhorse for damage which may have occurred in transit After removing the components from the shipping container s check the container for any loose parts Remove all packing materials Visually check all air passages of power source for any packing materials that may obstruct airflow through the welder If the equipment is not being installed immediately store it in a clean dry well ventilated area until installation 3 2 Selecting a Location The location of the power source should be carefully selected to ensure satisfactory and dependable service Choose a location relatively close to a properly fused source of electrical power Use care against toppling over if the machine is placed on a tilted surface or plane It is important that the machine be located in an open area where air can circulate freely through the front and rear openings If space is at a premium leave at least 1 foot 300 mm of clearance between the rear of the power source and wall or other obstruction 3 3 Selecting Suitable Supply Cables The standard power input cab
20. e always have trained support personnel nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe 3 Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arcs can react with vapors to form highly toxic and irritating gases 4 Do not weld on coated metals such as galvanized lead or cadmium plated steel The coating must be removed from the area to be welded Coatings and metals containing above elements can generate toxic fumes when heated to welding temperature 1 6 WELDING SPARKS A Heat from flames and arcs can start fires Hot slag or sparks can also cause fires and explosions 1 Remove all combustible materials from the work area or cover these materials with a protective non flammable tarp Combustible materials include wood fabrics sawdust liquid and gas fuels solvents paints and coatings paper etc 2 Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire Make certain that such openings are protected from hot sparks and metal 1 7 ELECTRIC AND MAGNETIC FIELDS Electric current flowing through any conductor causes localized Electro Magnetic Fields EMF Welding and cutting current creates EMF around welding cables and welding machines 1 Operators having pacemakers should consult their physician before welding EMF may interfere with
21. g operations Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric arc or hot metal 3 Wear flameproof type gloves heavy long sleeve shirt cuff less trousers and a welding helmet or cap for hair protection to protect against arc rays and hot sparks or hot metal A flameproof apron may also be desirable as protection against radiated heat and sparks 4 Hot sparks or metal can lodge in rolled up sleeves trouser cuffs or pockets Sleeves and collars should be kept buttoned and open pockets eliminated from the front of clothing 2 PRODUCT DESCRIPTION AND INFORMATION 2 1 INTRODUCTION TO THE STUDHORSE 1200DM amp STUDHORSE 1000DM The Studhorse 1200DM and 1000DM machines are portable drawn arc Stud welders using an inverter type power supply to generate the output power Both machines are currently available in the following models 400V three phase or 480V three phase 10 2 2 PRODUCT SPECIFICATIONS Stud Welding Open Input Amperes at Physical Weight Welding Range Circuit Rated Load Efficiency Dimensions Current Amps Voltage Output 50 60 Hz 1200DM 1200A 6 Height 17 9 45 5cm Width 10 5 80165 35 23 8 79 60 26 cm 36 3 kg 41 0kg 10 E Dp 20 1000DM 1000A Depth 19 5 6 49 5cm 400V or 480V three phase Slow Blow Fuse three phase supply voltage is connected to a circuit breaker and then to a six pulse rectifier
22. it 4 Adjust the Welding Current Control and the Stud Timer Control to fit the type and diameter of weld stud to be used according to the table in section 4 4 1 16 4 4 1 Factory Suggested Weld Set points Recommended Current and Time Settings Stud Size Current Time Inches Metric Amps Seconds 1 4 6mm 450A 0 20 5 16 8mm 550A 0 25 3 8 10mm 650A 0 35 1 2 12mm 850A 0 55 5 87 16mm 1000A 0 90 5 8 16mm 1200A 0 70 9 4 19mm 1200A 1 00 Maximum for 1000DM model Maximum for 1200DM model Example 1 If 1 2 inch studs are to be welded set the current to 850 Amps and the time setting to 0 55 Seconds 2 Shoot weld stud 4 4 2 Digital Time and Setting Operation Depending on the length of your welding and gun cables the measured current may vary The measured current will be displayed on the current display for 3 seconds After 3 seconds the set value will be displayed again The time and current settings will vary with the gun s lift and plunge settings A good weld is characterized by an even collar formation a shiny bluish tint to the collar surface a slight flow of collar metal into the base material good collar height consistant stud length after the weld and a full circle collar around the stud circumfirence after the weld 17 4 4 3 Discharging the Current after a test fire the Stud is not welded WARNING ELECTRIC SHOCK CAN INJURE OR KILL The gun and ground circuits are ele
23. le for The Studhorse 1200DM and 1000DM welder is a high quality 10 Gauge cable that is 12 5 feet long The secondary cables that connect the Stud gun to the power source vary with manufacturers but is normally 1 0 gauge and 8 feet in length Heavier 2 0 gauge cables can be used to extend the distance between the machine and work surface otandard ground cables are 1 0 gauge with 25 feet maximum length Cable lengths can total 50 feet total primary length plus total secondary length using heavier 2 0 cables WARNING e Only qualified personnel should perform this installation e Turn the input power off at the disconnect switch or fuse box before working on The Studhorse e Do not touch electrically hot parts 12 3 4 Connecting input power The standard factory installed input power cable measures 12 5 ft A longer power cable have been provided as an option if requested The primary cable supplied with the power source has 4 conductors When connecting an attachment plug or hard wiring to an electrical service box connect the green yellow wire to the ground The remaining 3 conductors can be connected to the phases in any order Once connected to the primary power the power source must be turned OFF before the unit is moved 3 5 Fuses and Circuit Breakers It is recommended that input fuse sizes be in accordance with the table below Input Voltage Welder input Recommended Maximum I Wan Fuse Capacity 400
24. limits the current through the SCRs should they fire at the same time The circuit breaker limits the time the current is flowing through the resistors Together they protect the SCR from destructive current should a cross firing of the SCRs occurs Even though the case of The Studhorse welder is made of non conductive fiberglass reinforced Polyester it meets and exceeds manufacturing and industry specifications 27 8 1 The Principles of the Inverter Design The inverter function is perhaps easiest understood using the simplified block diagram below AC INPUT p MAIN INVERTER TRANSFORMER RECTIFIER RECTIFIER CONTROL OUTPUT FILTER AUXILIARY TRANSFORMER WELDING OUTPUT FIGURE 8 1 28 8 2 Main Circuit Diagram m cc eT 71 ee ee screen ee NS ce CAPACITOR BOARD RV CZ ES GND P gt ce GROUND STUp 5 DE RESISTORS 22 HEATSINK 1 FT wa 2 A i op 4 L I c on HEATSINK MAIN XFMR T DUTPUT gt DIDDE HEATSINK I HEATSINK 2 I L AA _ ASSEMBLY _ _ _ L J J6 J5 HEATSI L 02 lt SCR S HEATSINK hn THERMOSTAT CONTROLLED FAN J13 On Pu ew POST PRE TITLE CURRENT TIME 573 WIRE GUN CONTROL
25. ltage 3 Call Factory or Authorized Service Center 1 Ensure correct input voltage to stud welder 2 Correct input 1 Correct incoming power 2 Go to larger gauge cable maximum of 50 of 2 0 cable 1 Pull trigger to initiate welding current See gun manual 25 TROUBLE F E10 flashing on display G Display has fluctuating amperage levels H Display is flashing Fan not working PROBABLE CAUSE REMEDY 1 No arc initiated when trigger 1 Clean surface was pulled between stud and work piece 2 Unit was dry fired e g the 2 Read gun manual for gun with stud was not pressed procedure against grounded piece of metal 3 Read gun manual for Trigger was pulled with gun procedure in the air 1 Unit is self calibrating and 1 Proceed after calibration will complete calibration after 2 4 studs 1 One of 5 temperature 1 Wait for several minutes for zones has overheated welder to cool down and display to stop flashing 1 Fan overheated 1 Allow unit to cool down for at least 10 minutes 26 8 ELECTRICAL SPECIFICATIONS amp DIAGRAMS Circuit breaker The 3 phase elecric input power is connected to circuit breaker K CF Assembly The CF assembly has three functions a six pulse rectifier suppression of elector magnetic interference EMI and suppression of input voltage surges from the power lines Rectifier The input rectifier consists of the power diodes CR1
26. nds to 1 00 second with 0 01 second accuracy in 01 second increments using the Time control knob 4 3 4 Process for various Stud welding positions Drawn Arc Stud Welding allows welding 1 4 to 3 4 diameter Studs made of non alloyed alloyed stainless and heat resistant steels to suitable base materials The following is a guide for welding positions using The Studhorse 1000DM and 1200DM machines Stud Welding Minimum Welding Process otud Diameter Plate Thickness Position With a Ceramic 1 4 to 3 4 One 1 4 Quarter Horizontal Ferrule Inch Vertical Overhead Using Inert Gas 1 4 to 1 2 One 1 4 Quarter Horizontal Inch Only Short Cycle Less than 1 2 16 Gauge Horizontal Vertical Overhead 15 4 3 5 Process Control Selection DIGITAL CURRENT amp TIMER METER POWER ON INDICATOR 4 3 1 GUN 4 4 4 CONTROL CONNECTOR CIRCUIT BREAKER gt 3 7 POWER ON OFF STUD TIMER CONTROL 4 3 3 4 4 1 WELDING CURRENT CONTROL 4 3 3 4 4 1 OUTPUT TERMINALS 3 6 INPUT POWER CORD 12 FT 8 65m LONG 3 4 4 4 Welding Operation All secondary outputs must be connected to output terminals of the power source 2 After the primary input connections have been made close the main wall disconnect switch or circuit breaker 3 Set the primary power selector to the ON position This will turn on the control circuitry The Power On light on the front panel will be l
27. ontact the factory to obtain replacement parts for this machine Customers that intend to submit a warranty request for corrosion related failure should contact the factory to obtain an RMA number before shipping their welder to the factory for evaluation 1 SAFETY Safety is 5 responsibility ARCON designs every machine with safety in mind and safe work environment depends largely on you Do not install operate or repair this equipment without carefully reading this manual and observing all of the safety precautions mentioned If there is a question ask your supervisor 1 1 Safety Symbols Every effort has been made to protect trained operators from injury or unnecessary risk Certain symbols are used throughout this manual to call attention to safety related information and instruction The safety symbols in this manual have the following meanings A This symbol indicates Dangerous Situations When this symbol is used in this manual death or serious bodily harm is possible or probable if the corresponding preventative measures are not taken Operators must take caution in the method and manner of handling or using the machine when this symbol is displayed 1 2 Safety Precautions Do not install operate or repair The Studhorse welding equipment without reading this manual and all safety precautions stated within This machine was designed and built with operator safety in mind but safety begins with you Every effor
28. pment LLC will be charged based on ARCON s applicable hourly labor rate and current replacement part prices Manufacturer s Limited Product Warranty ARCON Welding Equipment s only warranty is that goods being sold will be free from defects in materials and workmanship This express warranty is in lieu of any other warranties either expressed or implied and whether statutory or otherwise including any implied warranty of merchantability or fitness for a particular purpose The Manufacturer s written warranty for The Studhorse 1200DM amp Studhorse 1000DM Welders has been included with your new machine and is limited to defect in materials or workmanship The original purchaser must furnish notice of defect or failure to ARCON Welding Equipment or one of Arcon s authorized repair centers using an approved Warranty Claim Form Forms can be downloaded from the company Web Site at http www arconweld com guarantee against corrosion related failures can be extended to five years by completing the Registration Form Any equipment that has been modified by any party other than ARCON Welding Equipment LLC or equipment that has been improperly installed improperly operated misused based upon industry standards improperly maintained or equipment which has been used for operation outside of specifications will not be covered under the manufacturers warranty ARCON Welding Equipment shall in no way be liable for any consequential damages ARC
29. r any loose or damaged parts 3 Check air passages of power source for any debris that may obstruct airflow through the welder 4 Monitor and schedule having the machine cleaned with compressed air by an authorized service center 24 7 TROUBLE SHOOTING GUIDE WARNING PLEASE OBSERVE ALL SAFETY PRECAUTIONS TROUBLE PROBABLE CAUSE REMEDY A Fan rotates no welding current A2 Unit shut down while welding fan runs display flashing B Circuit breaker trips C Fan rotates slowly D Reduced output E Unit has no O C V or output Gun Remote Cable not plugged in Gun Remote Cable is defective Trigger was pulled within 6 seconds of last weld Overheated because duty cycle was exceeded inadequate flow of cooling 1 Over voltage or spikes 2 Incorrect voltage 3 Defective component 1 Incorrect input voltage to stud welder 2 Missing ohase 1 One phase of 3 primary input missing 2 Incorrect cable length gauge setup 1 Gun trigger not pulled to initiate welding current 1 Plug in Gun Remote Cable and recheck unit 2 Try a different gun possible problem with gun trigger for example 3 Wait 15 seconds before shooting next stud 1 Allow unit to cool for 10 minutes reduce duty cycle 1b Make sure that intake and exhaust vents are not blocked In heavy dust areas clean unit out once per month with compressed air 1 Reset breaker 2 Hook to correct vo
30. s machine was developed and tested on oilrigs in the North Sea decades ago This protection enhances reliability prolongs component life and adds value to all of ARCON s rugged line of portable welding power sources Listed below are some of the steps ARCON Welding has taken to increase corrosive atmosphere resistance in this machine Transformer vacuum impregnated twice and dipped an additional time Auxiliary transformer protected and coated to resist corrosion Output board encapsulated in repair friendly material to eliminate the failures Control board coated to protect against salt water arc over Input board coated to protect components from corrosion Resistors replaced with porcelain coated ceramic resistors Fan motor totally encapsulated winding coil to withstand corrosive conditions Terminal screws coated to prevent electrical arc overs This anti corrosion process comes with ARCON s five year manufacturer s guarantee against corrosion related electrical failure within natural operating environments This warranty begins the day the machine was shipped from the factory and does not apply to equipment used in man made environments that produce chemical residue dust or airborne debris of man made substances etc Because the Seahorse protection is incorporated in the manufacturing process any circuit modifications repairs or component replacement with non ARCON parts will void the Seahorse guarantee Repair centers should c
31. some type of pacemakers 2 Exposure to EMF may have other health effects which are unknown 3 Operators should use the following procedures to minimize exposure to EMF a Route the work cables together Secure them with electrical tape when possible b Never coil the work cable around any part of your body c Do not place your body between the work cables Route cables on the same side of your body d Connect the work cable to the work piece as close as possible to the area being welded e Keep welding power source and cables as far away from your body as possible 4 Electromagnetic fields can permanently erase magnetic data carriers computer memory credit cards security ID cards or data storage diskettes 5 Electromagnetic fields may magnetize and damage watches or similar digital devices 1 8 PROTECT YOURSELF AND OTHERS oome welding cutting and gouging processes are noisy and require ear protection The arc like the sun emits ultraviolet UV and other radiation and may injure skin and eyes Hot metal can cause burns Training in the proper use of welding processes and equipment is essential to prevent accidents 1 Always wear safety glasses with side shields in any work area In conjunction with eye protection welding helmets or face shields are also required 2 Use a face shield fitted with the correct filter cover plates to protect your eyes face neck and ears from sparks and rays of the arc when operating or observin
32. t has been made to protect the trained operator from injury Please become familiar with the information in this manual to minimize the risk of shock or injury STUD WELDING CAN BE HAZARDOUS ALWAYS PROTECT YOURSELF AND OTHERS FROM POSSIBLE INJURY OR DEATH KEEP CHILDREN AWAY OPERATORS WHO WEAR A PACEMAKER SHOULD CONSULT WITH THEIR PHYSICIAN BEFORE OPERATING STUD WELDING EQUIPMENT THIS OPERATOR S MANUAL SHOULD ALWAYS BE KEPT WITH THE STUDHORSE MACHINE FOR QUICK REFERENCE ALL SAFETY WARNINGS SIGNS AND STICKERS MUST STAY ATTACHED TO THE MACHINE ALL OPERATORS MUST BE PROPERLY TRAINED AND PROTECTED BEFORE OPERATING THIS EQUIPMENT 1 3 ELECTRIC SHOCK Precautionary measures must be taken to provide maximum protection against electrical shock aloo m 9 10 11 12 1 4 1 Electric shock can injure or Kill WARNING Do not touch live or energized electrical parts or store metallic objects near power Ground the work or metal to be welded to a good electrical earth ground Do not leave an energized machine unattended Never work in wet clothing gloves or footwear Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground Inspect all system components protective equipment cables connectors and gas lines prior to operating equipment Never use cables that are longer than necessary
33. to CR6 MOVs Metal Oxide Varistors If the machine is subject to a voltage surge btween phases the diodes are protected by MOVs MOVs are used from phase to ground RV1 RV3 and RV6 and also between phases RV2 RV4 and RV5 The phase to ground MOV protects the diode from a voltage surge between phase and ground MOVs RV1 to RV6 protect the machine from high voltage surges MOV is capable of withstanding surges of up to 40 000 Amps EMI Electro Magnetic Interference The Electro Magnetic Interference from the inverter is suppressed by two capacitors in parallel between phase and neutral These capacitors C2 C3 C5 C6 C7 and C8 must be of type X to be allowed to be connected between phases and also to comply with the European community CE norms The type X capacitors are connected to a common point making it a virtual neutral This point is connected to safety ground via two type Y capacitors and one 33 ohm resistor The capacitors must be of a very reliable HiRel version type Y as a malfunction might make welding machine in a steel case carry 480 V AC and therefore could be life threatening to the operator The 480 V version of The Studhorse must have two type Y capacitors in series to comply with the CE norms and be allowed to be sold to the European Community EC The T1 auxiliary transformer is connected to two of the 3 phases It is protected by an internal thermal switch t The surge resistors R1 and R2
34. tud welder An authorized ARCON Service Center must do all maintenance and repairs that require opening the case lf The Studhorse does not operate properly stop work immediately and investigate the cause of the malfunction Please note Opening up the case voids the Warranty Maintenance and repair should only be performed by an authorized ARCON Service Center or by the factory Do not permit untrained persons to inspect clean or repair The Studhorse Please call the factory for the location of the Authorized ARCON Service Center nearest you oince there are no moving parts other than the fan in the power source basic preventive maintenance only involves keeping the welder clean and free from metallic dust Periodically you should ask your Authorized Service Center to remove the cover from the case remove accumulated dust and dirt from the air passages and the interior components using clean low pressure air It is imperative that the air passages to the interior of the unit be free of dirt to ensure adequate circulation of cooling air especially over the rectifier bridge plates The frequency of cleaning will depend on the location of the unit the amount of dust in the atmosphere and number of operating hours Operators are encouraged to check the following to maintain The Studhorse power supply 1 Visually inspect the case panels handles and cables for damage which may occur in transit and in normal use 2 Check the machine fo
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