Image Industries Smartweld SW1200 Operation Manual Download

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Parts

List

Section 9

230/460 60 hz Parts List

SW1200

SW2000

SW1200

SW2000

01 Sheet Metal Top

Rectifier Assembly

PAE1050

PBE1050

02 Sheet Metal Left Side

PAS242

PBS242

Single Phase Filter Network

Sheet Metal Right Side

PAS241

PBS241

AC Surge Network

Schematic Decal

SCR Harness

04 Cross Brace

Single Sided Heatsink

05 Multigun SCR Support Pan

Spring Pin Locator

A-Arm Left Front / Right Rear

Thermal Paste

A-Arm Right Front / Left Rear

28 Double Sided Heatsink

07 Front Sheet Metal Reinforcement Bracket

29 Weld SCR

ESR55006PK

ESR75006PK

08 Base Pan

30 SCR Clamp 1200A

PAM200

PBM200

09 Chassis Leg

31 Snubber Diode

10 Front Sheet Metal Assembly

32 Snubber Diode Bracket

11 Rear Sheet Metal

33 Rectifier Buss Bar

Auxillary Module Tray

Steering SCR Assembly

Voltage Jumper Decal

Steering SCR Heatsink

Jumper Wire T1

Steering SCR

Jumper Wire T2

Steering SCR Clamp

Jumper Wire T3

Isolation Flat Washer

Delta Jumper Wire T1-T3

Isolation Shoulder Washer

Rectifier Bracket Right Side

Common Side Jumper

Rectifier Bracket Left Side

Multi-gun Steering SCR Harness

Isolation Flat Washer

Memory Module Blanking Plate

Isolation Shoulder Washer

Memory Module Assembly

Finish Panel (standard)

Weld Output Blanking Plate

Finish Panel (Robot/HLC connector)

Standard Weld Output (3 Hole)

Transformer 60hz

PAE501

PBE501

Weld Output with Gas (4 Hole)

Transformer 50hz

PAE500

PBE500

Weld Output with Autofeed (7 Hole)

16 Weld Choke

PAE600

PBE600

Small Module Blanking Plate

17 Cooling Fan Assembly

Data Recorder Module

Contactor 1200A

PAE101

PBE101

Gas Control Module

Control Transformer

Panel Mount Weld Cable Connector (Red)

Control Transformer Fuse

Panel Mount Weld Cable Connector (Black)

Fan Capacitor

Gas Connector Panel Mount

Fan Capacitor Mtg Bracket

Gun Control Cable Panel Mount Connector

Terminal Strip

Feeder Bowl Cable Panel Mount Connector

Terminal Strip Jumper Link

Autofeed Air Line Bulkhead Connector

20 Protective LCD Screen Shield

Gas Manifold

21 Current Transducer 1200A

ECT1000

ECT1500

Gas Valve

Main PCB (right side)

Gas Valve Station Plug

Multigun/Autofeed Board (Left Side)

Autofeed Air Manifold

23 Control Panel

PAM1300

PBM1300

Autofeed Valve

User Interface Assembly

Autofeed Valve Station Plug

Rotary Knobs

Multi-gun / Autofeed Blanking Plate

Ribbon Cable to Main Board

Multi-gun User Interface

25 Power Switch

Mutli-gun / Auto Feed User Interface

Items Not Shown

42 Robot / High Level Control Harness

44 Weld Output Filter

PAE801

43 Multi-gun Ground Jumper Link

45 Cable 1200A Rectifier to Choke

CW3KK-1.3

CW5LL-1.3

Items Not Shown

46 Cable 1200A Choke to Ground

CW34K-2.3

CW5ML-2.3

52 Incoming Power Cord Grip

ECG150P

47 Cable 1200A Rectifier to Gun

CW34K-3

CW5ML-3

53 Rear Sheet Metal Hole Plug

PNP75

48 Control Panel Retention Straps

PAM71

54 Ribbon Cable Main PCB to MG PCB

PAH006

49 Retention Strap Spring

PAM72

55 Power Cable Main PCB to MG PCB

PAH005

50 Main Wiring Harness

PAH002

56 Autofeed Solenoid Harness

PAH008

51 Multi-gun/Autofeed Aux Power Harness

PAH003

57 Bridge Thermoswithch 60C

PAE903

PAE1203

PAH017

PAE80

PAE3

PNVA24-4

PNMB-PLUG

PAS130A

PAE1202

PNMA-4

PNVA24-2

PNMA-PLUG

PNMB-4

PNBQ-156B

PAH014
PAH015

PNB25T25TS

PAE2103
PAE2101

CCL1/0RFR
CCL1/0RFB

PAM1110
PAM1120
PAM1130

PAS120A

PAH016

PAS140A

PAE2102

PAM1100

ESR120002PK

PAM202

WFN43-62-31

PAE80

PAM50

PAE1001
PAE1060

PAM4

SPC12-37ZP

ETP

PAM3

ED5004

PAH004

Item

Description

Part Number

WSN25-62-50x42-39

PAE800
PAE802

PAH001

PAM2

PAP1201B

PAE2000

PAM110

PAK101A

WFN43-62-25

PAM250
PAM251

ETC440/220-110-50

PAM1301

PAP101C

PAC261

PAK111A

PAE902

PAS240

PAD241
PAC280
PAC281

Item

Description

Part Number

WSN25-62-50x42-39

PAC221
PAC201

PAS225
PAS230

PAK102A

EFFNM-1

EC370-6

ECB-1

ETB70-12

ETBJ70

PAK125

PAD125

PAH013
PAH012
PAH011
PAH010

PAC260

Summary of Contents for Smartweld SW1200

Page 1: ...o read AWS SP Safe Practices available from the American Welding Society DO NOT permit untrained persons to install operate or maintain this equipment DO NOT attempt to install or operate this equipme...

Page 2: ...revision Degrees of Protection provided by Enclosures IP code IEC 529 1989 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests IEC 664 1 1992 Ele...

Page 3: ...oods sold will be free from defects in workmanship and material This warranty is expressly in lieu of other warranties expressed or implied or for fitness for a particular purpose The liability shall...

Page 4: ...ance damage improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer WARNING These Safety Precautions are for your protection They summa...

Page 5: ...tical 8 DO NOT use welding current in damp areas if movement is confined or if there is danger of falling 9 Properly install and ground this equipment according to this Owner s Manual and national sta...

Page 6: ...4 1 8 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 9 Do no...

Page 7: ...prior to service to prevent the fan from starting unexpectedly H F RADIATION CAN CAUSE INTERFERENCE 1 High Frequency H F can interfere with radio navigation safety services computers and communicatio...

Page 8: ...CSA Standard W117 2 Code for Safety in Welding and Cutting American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org 1 ANSI Standard Z87...

Page 9: ...Safety Precautions Section 1 Symbols and Definitions...

Page 10: ...nit will go into thermal shut down Storage and Operating Environment The Power Supply or Welding Unit should be located on a flat level floor It should not be tilted more than 15 in any direction duri...

Page 11: ...ith gas cylinders Detach and move gas cylinders separately 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit...

Page 12: ...ting device without locking facilities attach a red tag to the device to warn others that the circuit is being worked on Connect the input conductors to the welding power source before making connecti...

Page 13: ...set before connecting electrical power to the welder for both the main transformer and control transformer Main Transformer Jumper Links All units from the factory are pre jumpered to the highest sel...

Page 14: ...14 Installation Set Up Section 2 230 Volt Jumper Configuration 60Hz 460 Volt Jumper Configuration 60Hz...

Page 15: ...is necessary to remove the right side cover Remove the screws retaining the right side panel Use a 3 8 nut runner socket or a large flat blade screw driver Strip back the outer cable jacketing so the...

Page 16: ...e next button push or knob turn will light the backlight again Home Screen The Home screen is either the Normal Operation screen or the Auto weld screen depending on the selected mode To weld the home...

Page 17: ...s have an acceleration feature built into them As you turn the knobs faster the values change by greater amounts When you turn the knobs slower the values change by small amounts For example you would...

Page 18: ...NT stands for No Thread FT stands for Full Thread PD stands for Pitch Diameter This feature is activated by the Auto Weld button on the front panel The green LED in the Auto Weld button will light ind...

Page 19: ...enance interval This also shows the maintenance alert set point When the actual welds since the last maintenance interval are greater than or equal to the maintenance alert set point the message Maint...

Page 20: ...n press the scroll down button 3 times to access the Hammer Mode screen This mode is most useful when welding on dirty rusty mill scale or painted surfaces painted surfaces require a special stud The...

Page 21: ...tions Option 1 All Locked All Features are locked and require the entry of a user code to adjust values Option 2 All Unlocked No Features are locked Option 3 Selective Locking Some Features are locked...

Page 22: ...erruption to the operators work flow Therefore error reporting may be turned off SET USER CODE UNLOCKING FEATURES Starting at the home screen press the scroll down button 7 times to reach the set user...

Page 23: ...een exceeded When the unit cools down the thermal overload protection will automatically reset After the thermal overload has reset the unit will function normally Shorted Weld SCR If the microprocess...

Page 24: ...ped pen to make your notes Do not use pencil or ball point pen because these will damage the write on surface The felt tip markings can be removed with a damp cloth Recalling Stored Settings To recall...

Page 25: ...t up the weld schedules as you like these settings can be saved in a Memory Preset location To save a schedule in a Memory Preset press and hold the desired memory preset button until the LED flashes...

Page 26: ...ogramming the pre flow and post flow timing See Screen sample to the left The upper rotary knob controls pre flow time while the lower rotary knob controls post flow time These times can be adjusted f...

Page 27: ...it below the Upper Limit For example the desired weld may be 500 amps Weld engineering may allow results which vary from the 500 amp target The limits might be set up as shown to the left This would...

Page 28: ...r Speed BAUD Rate screen Capturing Output Data Once installed the data recorder module will ALWAYS report weld data If weld data is not required the printer port can be left unconnected The data is no...

Page 29: ...be exceeded To change weld parameters for a given weld tool press the control button for that weld tool Note if you only have 2 weld tools installed and press the control button for GUN3 or GUN4 nothi...

Page 30: ...similar to SCSW but adds shielding gas to prevent porosity Standard Drawn Arc Stud Welding DASW with ferrule The stud is loaded into the stud weld tool or weld head chucking mechanism the ferrule also...

Page 31: ...may over ride weld quality and this process may be chosen Gas Arc Short Cycle Stud Welding GASCSW This process combines GASW and SCSW This uses the short cycle process but adds shielding gas to elimin...

Page 32: ...eral application The other types are subject to air harden ing and they tend to be brittle in the weld area unless annealed after welding The weldable stainless steel grades include American Iron and...

Page 33: ...g or grinding Prior to welding surface areas to which studs will be welded should be clean and free of foreign matter including the following 1 Paint 2 Moisture 3 Heavy oxide film 4 Oil grease indelib...

Page 34: ...ition Generally 10ft3 hr 9l min is a good starting point for gas flow however the shielding gas flow rates recommended by the stud manufacturer should be used Other Materials On a moderate scale stud...

Page 35: ...Verify that set current falls within the SPC target points Changes were made to gun setup Verify gun lift and plunge settings There was a significant change to weld materials If there was a significan...

Page 36: ...ld time Turn off error reporting Page 16 Improper electrical connection Verify all electrical wiring Verify fuses Stud Gun Malfunction Clean Adjust Stud Gun Weld Time Below 0 150 Secs Reduce gun lift...

Page 37: ...afety Issue Failure in the main weld rectifier Shorted weld SCR The safety circuit has detected a short and has shut the power supply down Send the unit it for repair Fusing The welder is exceeding th...

Page 38: ...ed to be replaced periodically estimated life of 2 years To replace this battery remove the power source front panel by removing 6 socket head button screws The data recorder module is retained to the...

Page 39: ...IRE 7 WIRE 16 WIRE 16 WIRE 18 WIRE 18 WIRE 17 WIRE 17 WIRE 20 WIRE 25 WIRE 25 WIRE 29 WIRE 23 WIRE 22 WIRE 23 WIRE 22 WIRE 24 WIRE 19 WIRE 20 WIRE 19 WIRE 19 WIRE 15 WIRE 15 WIRE 14 WIRE 14 WIRE 13 WI...

Page 40: ...40 Parts List Section 9 230 460 60 Hz Parts List...

Page 41: ...eeder Bowl Cable Panel Mount Connector Terminal Strip Jumper Link Autofeed Air Line Bulkhead Connector 20 Protective LCD Screen Shield Gas Manifold 21 Current Transducer 1200A ECT1000 ECT1500 Gas Valv...

Page 42: ...42 Schematic Diagram Section 10...

Page 43: ...WER LIGHT T1 T2 T3 WIRE 4 WIRE 3 WIRE 2 WIRE 1 WIRE 25 WIRE 28 WIRE 6 WIRE 7 WIRE 16 WIRE 16 WIRE 18 WIRE 18 WIRE 17 WIRE 17 WIRE 20 WIRE 25 WIRE 25 WIRE 29 WIRE 23 WIRE 22 WIRE 23 WIRE 22 WIRE 24 WIR...

Page 44: ...44 Parts List Section 11 220 380 50 Hz Parts List...

Page 45: ...tective LCD Screen Shield Gas Manifold 21 Current Transducer 1200A ECT1000 ECT1500 Gas Valve Main PCB right side Gas Valve Station Plug Multigun Autofeed Board Left Side Autofeed Air Manifold 23 Contr...

Page 46: ...46 Menu Tree Appendix A STANDARD MENU TREE This is a quick reference to find a specific welder function This is the basic menu tree that comes standard with all power supplies...

Page 47: ...he display screen by pressing the corresponding control button on the optional module With multiple weld tools there are no additional menu trees However the settings in the standard menu tree and opt...

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