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Safety

  Precautions

Section 1     

eQUIPMeNT MAINTeNANCe - 

Faulty or improperly maintained equipment can cause injury or 
death.  Therefore:

1)  Always have qualified personnel perform the installation,   
  troubleshooting, and maintenance  work.  Do not perform  
  any electrical work unless you are qualified to do the work.

2) 

Before performing any work inside a power source, disconnect the power 
source from the incoming electrical power using the disconnect switch at the 
fuse box before working on the equipment.

3) 

Maintain cables, grounding wire, connections, power cord, and power supply 
in safe working order.  Do not operate any equipment in faulty condition.

4) 

Do not abuse any equipment or accessories.  Keep equipment away from:

 

 

- heat sources such as furnaces

 

 

- wet conditions such as water puddles and inclement weather

 

 

- oil or grease

 

 

- corrosive atmospheres.

5) 

Keep all safety devices and cabinet covers in position and in good repair.

6) 

Use equipment only for its intended purpose.  Do not modify it in any 
manner.

fALLING UNITS CAN CAUSe INJURY -

1)  Use lifting eye to lift unit only, NOT running gear, gas  

 

  cylinders or any other accessories.
2)  Use equipment of adequate capacity to lift and support unit.
3)  If using lift forks to move unit, be sure forks are long enough 
to extend beyond opposite side of the unit.

OVeRUSe CAN CAUSe OVeRheATING -

1)  Allow cooling period; follow rated duty cycle.
2)  Reduce current or reduce duty cycle before starting to weld  
  again.
3)  Do not block or filter airflow to unit

STATIC (eSD) CAN DAMAGe PC BOARDS -

1)  Put on grounded wrist strap BEFORE handling boards or   
parts.
2)  Use proper static-proof bags and boxes to store, move or  
  ship PC boards.

MOVING PARTS CAN CAUSe INJURY -

1)  Keep hands, hair, loose clothing and tools away from moving  
  parts.
2)  Keep away from pinch points such as drive rolls.

WeLDING WIRe CAN CAUSe INJURY -

1)  Do not press weld tool (weld tool) trigger until instructed to 
do so.
2)  Do not point weld tool toward any part of the body, other 
people or any metal when threading welding wire.

MOVING PARTS CAN CAUSe INJURY -

1)  Keep hands, hair loose clothing and tools away from moving  
  parts such as fans.
2)  Keep all doors, panels, covers and guards closed and  

 

  securely in place.
3)  Always disconnect electrical power 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 communications equipment.
2)  Have only qualified persons familiar with electronic  

 

  equipment perform this installation.
3)  The user is responsible for having a qualified electrician    
promptly correct any interference problem resulting from the 

installation.

4)  If notified by the FCC about interference, stop using the equipment at once.
5)  Have the installation regularly checked and maintained.
6)  Keep high-frequency source doors and panels tightly shut, keep spark gaps at 

correct setting, and use grounding and shielding to minimize the possibility of 

ARC WeLDING CAN CAUSe INTeRfeReNCe -

1)  Electromagnetic energy can interfere with sensitive electronic  
  equipment such as computers and computer-driven  

 

  equipment such as robots.
2)  Be sure all equipment in the welding area is electro-  

 

  magnetically compatible.
3)  To reduce possible interference, keep weld cables as short as  

possible, close together, and down low, such as on the floor.

4)  Locate welding operation 100 meters from any sensitive electronic equipment.
5)  Be sure this welding machine is installed and grounded according to this 

manual.

6)  If interference still occurs, the user must take extra measures such as moving 

the welding machine, using shielded cables, using line filters, or shielding the 
work area.

eMf Information

Considerations about welding and the effects of low frequency Electric and Magnetic 
Fields (EMF):
Welding current, as it flows through welding cables, will cause electromagnetic 
fields.  There has been and still is some concern about such fields.  However, after 
examining more than 500 studies spanning 17 years of research, a special blue 
ribbon committee of the National Research Council concluded that: “The body of 
evidence, in the committee’s judgement, has not demonstrated that exposure to 
power-frequency electric and magnetic fields is a human-health hazard.”  However, 
studies are still going forth and evidence continues to be examined.  Until the final 
conclusions of the research are reached, you may wish to minimize your exposure 
to electromagnetic fields when welding or cutting.  See section on EMF on page 2.

   

hOT PARTS CAN CAUSe SeVeRe BURNS - 

1)  Do not touch hot parts with bare hands.
2)  Allow cooling period before working on welding tool (weld 
tool              

 

 

 

or torch).

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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