Image Industries Smartweld SW1200 Скачать руководство пользователя | Manualshive

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Operation

Manual

ILM001K

Sept, 2008

Drawn Arc Stud Welding Power Source
SW1200 & SW2000

For firmware version 1.8 and later
For serial number B8BA024 and higher
Mfg. after 07-29-08

CAUTION

TheSe INSTRUCTIONS ARe fOR exPeRIeNCeD OPeRATORS.

If you are not fully

familiar with the principles of operation and safe practices for arc welding equipment, we urge you to
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 equipment until you have read and fully understand these
instructions. If you do not fully understand these instructions, contact your supplier for further
information. Be sure to read the Safety Precautions before installing or operating this equipment.

BE SURE THIS INFORMATION REACHES THE OPERATOR. EXTRA COPIES ARE AVAILABLE THROUGH YOUR SUPPLIER.

Price $5.50 USD

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Содержание Smartweld SW1200

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 42: ...42 Schematic Diagram Section 10...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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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