Pro-Weld ARC 1850 User manual

OPERATION/MAINTENANCE
MANUAL

ARC 1850
PRO WELD
PAGE
1.0 INTRODUCTION....................................................... 1
2.0 WARRANTY............................ ................................... 1
3.0 UNPACKING YOUR UNIT....................................... 1
4.0 SUGGESTED SAFETY PREC AUTIONS.......…....... 1
4.1 PERSONAL SAFETY PRECAUTIONS……………. 1
4.2 POWER SUPPLY SAFETY PRECAUTIONS…….. 2
5.0 GENERAL DESCRIPTI ON..........................…........... 2
6.0 ELECTRICAL INPUT REQUIREMENT.......…........ 2
7.0 CONTROL PANEL DESCRIPTION..... ........…........ 4
8.0 WELD GUN SETUP.........................................…........ 5
8.1 PLUNGE LENGTH.................... ................................. 5
8.2 CHECKING GUN LIFT....................................…....... 6
9.0 PARTS LIST.......... ..........................................…........ 7thru13
10.0 TROUBLE SHOOTING...................................…....... 15
LIST OF FIGURES
1 JUMPER LINK ARRANGEMENT...................…...... 3
2 CONTROL PANEL FRONT.........................…........ .. 4
3 STANDARD GUN SET - UP..........................…............ 5
4 FUSE BLOCK................................................. .............. 6
5 CONTROL UNIT - FRONT......................................... 7
6 CONTROL UNIT - REAR.......................... ................. 8
7 CONTROL UNIT - SIDE VIEW................................ 9
8 RECTIFIER, WELD BRIDGE ASSY................…... ... 10
9 PRINTED CIRCUIT BOARD ENCLOSURE.…...... 11
10 GUN TIMER CONTROL PCB................................... 12
11 MONITOR PCB.. ......................................................... 13
12 CURRENT CONTROL PCB..............................…..... 14
TABLE OF CONTENTS

ARC 1850
PRO WELD

ARC 1850
PRO WELD

ARC 1850
PRO WELD

ARC 1850
PRO WELD

ARC 1850
PRO WELD
PAGE 1
1 .0 INTRODUCTION
Your new stud welding equipment has been carefully co n-
structed using the finest components and material available.
Used properly, this equipment will give you many years of
profitabl e, efficient service.
The system incorporates the latest in engineering advances
for complete, reliable end welding of mild ste el, stainless
steel and aluminum fasteners.
A careful study of this manual will enable you to understand
how the welder operate s 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 asse m-
bly in the welder. The assembled welder is completely pe r-
formance checked. The welder is delivered to you in fun c-
tional electro -mechanical condition.
All parts used in the assembly of the welder and its
accessories are fully warranted for 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 wa rranty, the manufacturer reserves the
right to repair or replace, at their option, defective parts
which fail during the guarant ee 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 mater i-
als furnished where such cost are not expressly authorized in
writing.
The manufacturer does not warrant any parts or acce s-
sories against failures resulting from misuse, abuse, improper
installation, maladjustment, or use not in accordance with the
op erating instructions furnished by the manufacturer. The
warranty is valid only when studs are purchased from sources
approved by the manufacturer or are of identical specific a-
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 u n-
packed, it is recommended that you inspect it for any phys i-
cal damage that may have occurred in shipping.
Y our 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
ve n tilation. Do not restrict the air flow around the front lou-
vers or from the fan at the rear of the unit. Do not allow w a-
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 recommend a-
tion to ANSI Z49.1, Safety in Welding and Cutting, and to
AWG Publication A6,1 - 66, Recommended Safe Practices for
Gas - Shielded A rc Welding.
4.1 Personal Safety Precautions
1. Always treat electricity with respect. Under open circuit
conditions, the welding machines output voltage may be da n-
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. Con sult 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. I n-
spect all cables frequently for insulation failures, exposed
wires, loose connections and repair as needed.
6. Don’t overload w elding 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 flamm a-
ble or toxic vapors when heated.

ARC 1850
PRO WELD
PAGE 2
9 . Be sure to provide proper ventilation when welding in a co n-
fined area.
10. Never look at the electric arc without wearing protective
eye shields.
11. Always use the proper protective cl othing, 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 manufa c-
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 disco n-
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 superior
strength over normal arc welding procedures.
Since the ARC - 1850 stud welding system provides the proper
arc length and allows you to select the proper arc time and
wel d ing current, the variables that affect weld quality are min i-
mized.
THE UNIT
The ARC - 1850 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 co n-
trol units. An added feature in the ARC - 1850 is the ability to
dial in the desired weld time and weld current before even
ma k ing a weld. By selecting the setup mode, the weld time and
current can be adjusted and displayed on the front panel’s dig i-
tal meters.
.
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 - 1850 system is capable of welding studs
from 12ga. to 3/4” diameter with precision and repeatability.
6.0 ELEC TRICAL INPUT REQUIREMENT
This welding power source is designed to be operated from
three - phase, 60 Hertz, AC power supply which has a line vol t-
age rating that corresponds with one of the electrical input vol t-
age shown on the nameplate or input data label. Consult 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 ARC - 1850 should be operated from a separate fused or
circuit breaker protected circuit. Install three primary leads plus
one gr ound 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 fr om the ground bolt. The other end of the ground lead
or cable should be attached to a suitable ground such as a water
pipe, gro und rod, etc.
This unit is equipped with input voltage jumper links either
installed or in a bag on the jumper link board to allow oper a-
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. I f necessary, reposition
the jumper links to match the line voltage being used. (see Fi g-
ure 6.1)

ARC 1850
PRO WELD
PRIMARY WIRE DELAY TYPE FUSE
SIZE - AWG GND SIZE IN AMPS
230V NO.1(2) NO.2 200
460V NO.4(6) NO.6 100
575V NO.4(6) NO.6 9 0
Figure 1
Jumper Link Arrangement
230V
L3L2L1
654321
1 654321 65432654321
L3L2L1
654321
1 654321 65432654321
L3L2L1
654321
1 654321 65432654321
460V
575V
Jumper Link connections
CAUTION
The stud labeled GND is connected to the unit chassis and
is for grounding purposes only. Do not connect a wire
from th e terminal labeled GND to one of the three - phase
line terminals as this may result in “hot” power unit cha s-
PAGE 3

ARC 1850
PRO WELD
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 act i-
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 ded i-
cated stud welding power supply with built in time and cu r-
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 p arameters. This
switch
must be in the weld position for the unit to weld.
TIME/CURRENT SWITCH
This switch selects either the weld time or weld current that
is to be displayed on the digital meter.
WELD TIME ADJUSTMENT
Select: SETUP, TIME and adjust th e time control knob until
the digital meter displays the desired time. Return setup
switch to WELD before attempting to weld. Th e weld time is
adjustable from .1 to 1.6 seconds.
W ELD/CURRENT ADJUSTMENT
Select: SETUP, CURRENT and adjust the current control
knob until the digital meter displays the desired current. R e-
turn setup switch to WELD, before attempting to weld. Weld
current is adjustable from 100 to 1900 amps.
DIGITAL PANEL METERS
D isplays weld time or weld current.
After a stud weld, the digital meter will automatically display
the actual weld parameters. The meter will automatically r e-
set and display the time or current for each weld.
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 “on” when the gun trigger is pressed.
GUN FAULT LED INDICATOR
The gun fault LED “on” indicates a shorted gun solenoid or a
shorted control cable. The LED will stay “on” and lock out
the gun from triggering.
THERMAL LED INDICATOR
The thermal LED “on” indicates the internal temperature has
reached the max imum rated temperature in either the weld
bridge or the main transformer. LED “on” will prevent the
gun from being triggered.
PAGE 4

ARC 1850
PRO WELD
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 s e-
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 duri ng 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 th e 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 co n-
tact occurs between the stud and the ferrule during retraction
or forward plunge of the stud.
3. The “plunge length” is the amount of the stud exposed b e-
yond the ferrule during initial set - up. Set the plunge by loo s-
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 fe r-
rule.
4. The lift height, which determines the arc length, has been
preset at the factory and will automatically lift and plung e 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. I m-
proper lift will cause unsatisfactory welds. Refer to par a-
graph 8 - 1 if it becomes necessary to a d-
5 . Make sure that the cables are connected to the power
source (standard set - up is straight polarity - Negative to co n-
troller (or gun) and Positive (ground cable) to the work su r-
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 ta ke up the “plunge length” and the ferrule will seat
against the base plate.
DO NOT MOVE THE GUN DURING THE WELD
CYCLE
8. Pull the trigger holding the gun completely still as above.
The gun will lift the stud from the base plate and draw an
arc. The end of the stud and the adjacent material of the base
plate, will be melted by the weld arc.
The gun will then plunge the stud into the molten pool, exti n-
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 ins pect -
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.
PAGE 5

ARC 1850
PRO WELD
Figure 4
FUSE BLOCK
(Dual gun version shown)
F12
F11
F10
F9
F8
F7
F6
F5
F4
F3
F2
25 AMP
SLO BLO
5 AMP
CERAMIC
1 AMP
1 AMP
1 AMP
1 AMP
1 AMP
25 AMP
SLO BLO
25 AMP
SLO BLO
1 AMP
1 AMP
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. Mea s-
ur ing the distance the stud or gun mechanism
moves equals lift - usually this can be easily done by visual obse r-
vation or simple measurement against a static ref-
erence point (i.e. the ferrule properly seated in the ferrule grip).
Recommen ded 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”
When it does become necessary to adjust lift, you do so by r e-
moving the rear cap from the gun. This will expose the
rear coil yoke assembly, the set screw and the lift adjusting screw
(Loos en the set screw to avoid damaging the threads
of the lift adjusting screw).
To increase lift: turn the lift adjusting screw out (counter cloc k-
wise).
To decrease lift: turn the lift adjusting screw in (clockwise).
Once the lift has been set, tighten the set screw and r eplace the rear
cap.
PAGE 6

ARC 1850
PRO WELD
1
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 Pan el Meter 103 - 0004
7 Green LED 108 - 0029
8 Amber LED 108 - 0030
9 Positive Output Terminal 102 - 0058
10 4 Pole Panel Mounted Conn ector 107 - 0001
9 10
11
1 6 7 5 2 3
4 8
PAGE 7

ARC 1850
PRO WELD
Figure 6 Control Unit
Rear
12 13
14
15 16
9.0 PARTS LIST
ITEM DESCRIPTION PART NUMBER
12 Fuse 6 amp 600 volt 102 - 0007
13 Control Transformer 105 - 0015
14 Fan Blade 14” 102 - 0083
15 Fan Motor 102 - 0085
16 Start Contactor 113 - 0017
PAGE 8

ARC 1850
PRO WELD
Figure 7 Control Unit
Side View
18 17
FRONT OF UNIT
9.0 PARTS LIST
ITEM DESCRIPTION PART NUMBER
17 Main Transformer 105 - 0023
18 Shunt 102 - 0107
PAGE 9

ARC 1850
PRO WELD
Figure 8
RECTIFIER, SCR ASSEMBLY
SIDE AND TOP VIEW
9.0 PARTS LIST
ITEM DESCRIPTION PART NUMBER
19 Weld SCR Thermostat 102 - 0032
20 Weld SCR Clamp 102 - 0109
21 Weld SCR 108 - 0058
19
20
21
PAGE 10

ARC 1850
PRO WELD
9.0 PARTS LIST
ITEM DESCRIPTION PART NUMBER
22 Choke Coil 105 - 0004
23 Time Control P.C.Board 600 - 0010
24 Current Control P.C.Board 600 - 0012
25 Monitor Control P.C.Board 600 - 0011
26 Time Control P.C.Board 600 - 0010
27 Fuse Block 104 - 0015
28 Sustai ning arc SCR 108 - 0042
29 Gun Discharge Capacitor 106 - 0024
Front of Unit
Figure 9
Printed Circuit Board Enclosure
Top and Side View
22
23
24
25
26
27 28
29
PAGE 11

ARC 1850
PRO WELD
PAGE 12
Figure 10
GUN TIME CONTROL P.C. BOARD
P/N 600 - 0010
21
ON
OFF
IC104
V112
C104
+
+
R122
IC103
R121
D122
R123 R124
C106
C107
D118
R130
R128
D125
V106
D126
R144
R131 R132
D119
D116
R145
D103
R114
C102 +
D117
ZD102
R119
IC102
D114
R118
R112 R125
C105
V109
V110
D113
R117
D115
R116
D112
D104
V108
R115
+
R141
R142
OP101
V103
D102
R103
R155
V111
D111
D139
OP104
R126
R127
R153
D124
ZD105
D127
C108
+
R139
R138
C110 +
R104
C109 +
R129 R120
V105
R137
OP
109
OP
105
C111
R149
R143
C103
R136 R135 R150 R134
C112
D140
OP
102
R102
R101 R110 R109
R108 R140
C101
+
D101
D133 D132 D135 D134
D138
R151
Q101
D107 D108
D106 D105
ZD103
ZD104
V102
R107
D121
R113
R105
IC101
R146
D109
VR101
R111
R154
OP
103
OP110
C115
R147
D110
C114
OP
106
C113
OP
107
OP
108
R133
D131 D130 D129 D136 D137
R152
D120
V104
V107
ZD101
R148

ARC 1850
PRO WELD
Figure 11
MONITOR P.C. BOARD
P/N 600 - 0011
PAGE 13
IC201
R231
V201
R226
R202
C202
R203
D201
C201 +
R206
OP203
C209
+
IC203 R211
R212
R213
R210
IC202
R207
R208
R209
R204
OP201
OP202
C204
C203
R215
OP205
OP207
OP213 OP209
C205
OP204
C206
+
D204
V202
R217
R216
D202
D203
R218
D207
OP208
R221
R220
V204
V203
R219
R234
OP210
ZD202
D209
OP206
R223
D205
D206
R225
V205
R224
D207
C208
+
R227
V206
V207
OP212
OP211
C207
R222
R235
D210
ZD203
D208
R228
R229
R230
VR201
ZD201
R232 R233
R201
R205
R214