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4.  OPERATION 

 

 

WARNING! 

 

PLEASE READ CHAPTER 1 REGARDING SAFETY 

 

4.1     General Description 

 
The  1200  Amp  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  5/8-inch  full-base  weld  studs  in  a 
variety of applications.  Duty Cycle at 1200 Amps is 6 per minute using 5/8-inch studs.   30 Amp 
Slo-Blow fuses provide protection for all input voltages. 
 

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  with  no  mechanical  contactor.    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.  
The Power-On indicator light will show that input power is being supplied to the machine.   

 4.3.2    Digital Meter on The DT1200i model 

 

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 ”(X)XXX” and actual Current is 
displayed as ”(X)XXX”. 

If display flashes, the machine has exceeded its temperature limits. Wait a few minutes until 
the display has stopped flashing, and you can resume welding. 

 

 

 

 

Содержание DT1200i

Страница 1: ...OTEK Birkedam 10 C DK 6000 Kolding Denmark Tlf 45 7550 5666 Fax 45 7550 4795 sales dabotek com www dabotek eu DABOTEK DT1200i P N 101201 1200 Amp Drawn Arc Stud Welder OPERATING MANUAL REVISED MARCH 2...

Страница 2: ...t 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 Goran Hedberg Design Engineer...

Страница 3: ...g and Unpacking the Welder 12 3 2 Selecting a Location 12 3 3 Selecting Suitable Supply Cables 12 3 4 Connecting Input Power 12 3 5 Fuse and Circuit Breaker Ratings 13 3 6 Output Connections and Stud...

Страница 4: ...the inverter design Figure 8 1 28 8 2 Main Circuit Diagram 29 8 3 Front Panel Drawing with part references 30 8 4 Rear Panel Drawing with part references 31 8 5 Chassis Plate Drawing 1 with part refer...

Страница 5: ...e and is limited to defect in materials or workmanship The original purchaser must furnish notice of defect or failure to DABOTEK Welding Equipment or one of DABOTEK s authorized repair centers using...

Страница 6: ...mer 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 coa...

Страница 7: ...tors 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 w...

Страница 8: ...energized supply line before moving a welding power source 9 Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible...

Страница 9: ...oatings 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 spa...

Страница 10: ...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 a...

Страница 11: ...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 2 3 SAFETY STANDA...

Страница 12: ...l 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 fron...

Страница 13: ...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 connec...

Страница 14: ...eld 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...

Страница 15: ...t will be 1100 Amps Normally the difference between set and measured is less and only one stud is needed for tuning in process The measured current may fluctuate up to 5 60 Amps 1200 Amps dependent on...

Страница 16: ...ER ON INDICATOR 4 3 1 4 4 4 WELDING CURRENT CONTROL 4 3 3 4 4 1 STUD TIMER CONTROL 4 3 3 4 4 1 CIRCUIT BREAKER POWER ON OFF 4 3 1 OUTPUT TERMINALS 3 6 INPUT POWER CORD 12 FT 3 65m LONG 3 4 GUN CONTROL...

Страница 17: ...m 550A 0 250 3 8 10mm 650A 0 350 1 2 12mm 850A 0 550 5 8 16mm 1200A 0 700 1 If 5 8 inch studs are to be welded set the current timer to 1200 Amps and the timer setting to 0 7 Seconds 2 Shoot weld stud...

Страница 18: ...rmal 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 dep...

Страница 19: ...uide 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 sho...

Страница 20: ...20 5 1 Visually Inspecting Welded Studs continued...

Страница 21: ...21 5 1 Visually Inspecting Welded Studs continued...

Страница 22: ...22 5 1 Visually Inspecting Welded Studs continued...

Страница 23: ...23 5 1 Visually Inspecting Welded Studs continued...

Страница 24: ...ing 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 Cen...

Страница 25: ...educe 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 B Circuit breaker trips 1 Over voltage or spikes 2 Inc...

Страница 26: ...air 1 Clean surface 2 Read gun manual for procedure 3 Read gun manual for procedure G Display has fluctuating amperage levels H Display is flashing 1 Unit is self calibrating and will complete calibra...

Страница 27: ...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 p...

Страница 28: ...ter Design The inverter function is perhaps easiest understood using the simplified block diagram below AC INPUT FIGURE 8 1 RECTIFIER INVERTER MAIN TRANSFORMER RECTIFIER OUTPUT FILTER CONTROL BOARD AU...

Страница 29: ......

Страница 30: ......

Страница 31: ...1 of 1...

Страница 32: ...1 of 1...

Страница 33: ...1 of 1...

Страница 34: ...1 of 1...

Страница 35: ...001 FAN ASSY 15 011216 001 FAN BLADE 17 011220 002 INDUCTOR OUTPUT 18 011230 001 INDUCTOR MAIN w PTC 19 011241 001 INDUCTOR COMMUTATING FRONT 20 011251 001 INDUCTOR COMMUTATING REAR 21 011272 001 TRAN...

Страница 36: ...1 CLAMP OUTPUT CAPACITOR 65 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 FO...

Страница 37: ...CAMLOCK WA1200 021 EXTENSION CABLE FOR REMOTE 32FT WA1200 031 WORK CLAMP HEAVY DUTY w 10FT 2 0 CABLE CAMLOCK WAP1200 011 CONNECTOR CAMLOCK MALE FOR CABLE WAP1200 012 CONNECTOR CAMLOCK FEMALE FOR CABL...

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