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Image Industries Smartweld SW1200 Operation Manual

Drawn arc stud welding power source
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Operation
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
BE SURE THIS INFORMATION REACHES THE OPERATOR. EXTRA COPIES ARE AVAILABLE THROUGH YOUR SUPPLIER.
C AUT ION
Manual
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.
ILM001K
Sept, 2008
Price
$5.50 USD

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Summary of Contents for Image Industries Smartweld SW1200

  • Page 1 ILM001K Sept, 2008 Price $5.50 USD Operation Manual 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 BE SURE THIS INFORMATION REACHES THE OPERATOR. EXTRA COPIES ARE AVAILABLE THROUGH YOUR SUPPLIER. TheSe INSTRUCTIONS ARe fOR exPeRIeNCeD OPeRATORS.
  • Page 2 Declaration of european Conformity NOTe This information is provided for the units with CE certification (see rating lable on unit). Image Industries Inc. Manufacturer’s Name: 11220 East Main Street Manufacturer’s Address: Huntley, IL 60142 USA www.imageindustries.com SMARTWeLD 1200 & SMARTWeLD 2000 ®...

  • Page 3: Table Of Contents

    Table of Contents Section 1 SeCTION Safety Precautions SeCTION Installation & Set Up SeCTION Normal Operation Basic Auto Weld Advanced Features SeCTION Optional Features Preset Memory Data Recorder Multi-Weld tool SeCTION Special Techniques SeCTION Trouble Shooting SeCTION System Maintenance SeCTION Schematic Diagram 60Hz SeCTION Part List 60 Hz...

  • Page 4: Safety Precautions

    Safety Precautions Section 1 U Se RS R eSPO NSIBIL IT Y This equipment will perform in conformity with the description contained in this manual and accompanying labels and/or inserts when installed, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically.
  • Page 5 Safety Precautions Section 1 ARC RAYS CAN BURN eYeS AND SKIN - eLeC TR I CAL ShO CK - The arc, like the sun, emits ultraviolet and infrared (visible and Contact with live electrical parts and ground can cause severe invisible) and other radiation and can injure skin and eyes.
  • Page 6 Safety Precautions Section 1 fU M e S A N D GA Se S - WeLDING CAN CAUSe f IR eS AN D Welding produces fumes and gases. Breathing these fumes and e x PLO SI ON S - gases can be hazardous to your health, particularly in confined Welding on closed containers, such as tanks, drums or pipes, can spaces.
  • Page 7 Safety Precautions Section 1 fALLING UNITS CAN CAUSe INJURY - MOVING PARTS CAN CAUSe INJURY - 1) Use lifting eye to lift unit only, NOT running gear, gas 1) Keep hands, hair loose clothing and tools away from moving cylinders or any other accessories. parts such as fans.
  • Page 8 Safety Precautions Section 1 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of Cali- fornia to cause birth defects and , in some cases, cancer. (California health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 9 Safety Precautions Section 1 Symbols and Definitions...

  • Page 10: Installation & Set Up

    Installation & Set Up Section 2 General Description pecification Dimensions H: 26.9” (69 cm) W: 22.1” (57 cm) L: 27” (69 cm) Weight SW1200 -approx. depending on options- 320-425 lbs (168-193 kg) Weight SW2000 -approx. depending on options- 590-645 lbs (268-293 kg) Supply Voltage US Specify Voltage 230 V 3 phase...
  • Page 11 Installation & Set Up Section 2 handling Instructions Mass of the SW1200 and its various parts and correct methods of handling them, e.g. by fork-lift or crane. Unit SHOULD NOT be moved with gas cylinders. Detach and move gas cylinders separately. Caution When Moving Lifting Eye Lifting Forks...
  • Page 12 Installation & Set Up Section 2 electrical ALL electrical connections should be made by a properly certified DANGER electrical professional. It is recommended that a line disconnect switch be installed in the input circuit to the welding power source. This provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever it is necessary to perform any work on it Before making the electrical input connections to the welding power source, “machinery lockout procedures”...
  • Page 13 Installation & Set Up Section 2 fusing / Cable Recommendations All Disconnect fuses ²) ²) SW1200 Gauge(mm SW2000 Gauge(mm should be delay type 230 V 100A 1(42.468) 150A 1/0 (53.475) 460 V 4 (21.151) 2 (33.631) The red, black and white wires on the incoming cable do not need a termination. The green (or green with yellow stripe) ground wire will need a ring terminal with a 1/4”...
  • Page 14 Installation & Set Up Section 2 230 Volt Jumper Configuration 60Hz 460 Volt Jumper Configuration 60Hz...
  • Page 15 Installation & Set Up Section 2 Control Transformer Similar to the main transformer, the control transformer also has configurable jumper links. These are located directly on the control transformer on the side nearest the front of the unit. The control transformer is located at the top of the auxiliary module (see diagram on preceding page) which also houses the contactor and the main transformer jumper block.

  • Page 16: Normal Operation

    Normal Operation Section 3 Controls Diagram Some features shown are optional. Screen Conventions Line 1 Welder Function   Line 2 Data Line Controlled by Upper Rotary Knob    Line 3 Data Line Controlled by Lower Rotary Knob ...
  • Page 17 Normal Operation Section 3 POWeR UP Press (to the right or towards the 1) and momentarily hold the power switch, located on the lower left side of the control panel.   The power supply initiates a self test. This test lasts approximately 5 seconds. ...

  • Page 18: Auto Weld

    Normal Operation Section 3 WeLDING There are several different stud welding processes that this welder can perform. Be sure that your stud weld tool is set up properly for the process you intend to use. See Section 5 for discussion of different processes. Position the weld tool against the work.
  • Page 19 Normal Operation Section 3 ReVIeW LAST WeLD ReSULTS This feature confirms that the weld results are consistent with the settings that have been selected. To see the actual time and current results of the last weld   press the scroll right button.

  • Page 20: Advanced Features

    Normal Operation Section 3 ADVANCeD feATUReS PILOT ARC Pilot arc control is an advanced topic. If you do not have a good understanding of the stud welding process do not adjust these values. The factory default   setting of 100 Amps for 0.050 seconds is sufficient for most stud welding ...
  • Page 21 Normal Operation Section 3 feATURe LOCKING This function allows restricted access to none, some or all of the power supply’s advanced features. This is beneficial for many circumstances:   • For companies trying to establish an ISO9000 style program this prevents ...
  • Page 22 Normal Operation Section 3 mode this feature does not apply - errors will always be reported. If this feature is on, all current under & over errors (errors 5, 13, 14, 15 & 17 See Trouble Shooting pages) will be reported in the display.
  • Page 23 Normal Operation Section 3 LANGUAGeS From the home screen press the scroll down button 8 times (or the scroll up button once) to access the Language Screen. This allows the unit to  display the screens in English, Spanish or French. The upper rotary knob selects ...

  • Page 24: Optional Features

    Optional features Section 4 PReSeT MeMORY MODULe This module stores 8 different weld schedules for EACH WELD TOOL. This module stores all the weld parameters for a given setting. These parameters include: Main arc time Main arc current Pilot arc time Pilot arc current Hammer Mode The module also stores settings for option features:...
  • Page 25 Optional features Section 4                                     ...

  • Page 26: Gas

    Optional features Section 4 GAS MODULe This module allows the use of shielding gas during welding. To access the gas     functions press the control button on the gas module. This brings up the gas menu on the display. This screen allows you to select the gas mode. The upper ...

  • Page 27: Data Recorder

    Optional features Section 4 DATA ReCORDeR MODULe This module preforms two functions: 1) It can output a data stream to a printer, lap-top or any other device capable of capturing serial ASCII data. 2) Accepts pre-programmed limits for time and current. The unit then compares the weld results to those limits. If the actual weld results fall above or below those limits welding is halted to allow for corrective actions.
  • Page 28 Optional features Section 4 Clearing errors: To clear an error press the reset button on the front panel. If the error screen is locked, it must be unlocked before the error can be cleared. Adjusting the Time and Date Press the scroll right button to activate the time change mode.

  • Page 29: Multi-Weld Tool

    Optional features Section 4 MULTI-WeLD TOOL The Multi-Weld Tool feature allows the welder to support 2 to 4 total stud weld tools. All switching is transparent to the operator. An operator can grab   any of the multiple weld tools and weld with that weld tool’s weld parameters. ...

  • Page 30: Special Techniques

    Special Welding Techniques Section 5 PROCeSS DISCUSSIONS This section is provided to give a brief overview of different stud welding processes. If you have additional questions, consult your distributor for additional information or refer to the “Recommended Practices for Stud Welding”; ANSI/AWS C5.4, American Welding Society, Inc.
  • Page 31 Special Welding Techniques Section 5 quence as DASW. At the end of the weld cycle gas post-flow begins. After the gas post-flow concludes the entire weld cycle is complete and the weld tool can be removed. While the actual weld arc times are similar to DASW there is typically gas pre-flow and post-flow times which add to the overall time per weld.
  • Page 32 Special Welding Techniques Section 5 Low Alloy Steel Generally, the high-strength, low alloy steels are satisfactorily stud welded when their carbon content is 0.15 percent or lower. This range fits the analyses of low alloy steels used in welding and forming operations. If the carbon content exceeds 0.15 percent, it may be necessary to preheat the work to a low preheat temperature to obtain desired toughness in the weld area.
  • Page 33 Special Welding Techniques Section 5 Shielding Gas Selection for Steels The choice of gas depends on two factors, weld penetration and appearance. Pure argon provides the best looking welds, but has the least weld penetration. To increase penetration C02 is added to the mix. C02 percentages range from 10% to 25% depending on the desired level of penetration.
  • Page 34 Special Welding Techniques Section 5 Shielding Gas for Aluminum Shielding gas for arc stud welding and drawn-arc capacitor discharge stud welding is generally argon of at least 99.95 percent purity. Helium may be used with large studs to take advantage of the higher arc energy (required for magnesium). The gas should be directed to the weld area with an adaptor foot, and permitted to flow only while the weld tool is held against the work in the welding position.

  • Page 35: Trouble Shooting

    Trouble Shooting Section 6...
  • Page 36 Trouble Shooting Section 6...
  • Page 37 Trouble Shooting Section 6...

  • Page 38: System Maintenance

    System Maintenance Section 7 SYSTeM MAINTeNANCe Power Source This system has been designed to be essentially maintenance free. The only recommended maintenance is to blow out the power supply once a year. Dirt, grinding dust and other contami- nates can accumulate over time and they deteriorate the power supply’s cooling performance. If the unit is located in a dirty environment the unit should be blown out more frequently.

  • Page 39: Schematic Diagram 60Hz

    Schematic Diagram Section 8 230/460 60 hz Schematic...

  • Page 40: Part List 60 Hz

    Parts List Section 9 230/460 60 hz Parts List...
  • Page 41 Parts List Section 9 230/460 60 hz Parts List Part Number Part Number Item Description Item Description SW1200 SW2000 SW1200 SW2000 PAS240 Sheet Metal Top Rectifier Assembly PAE1050 PBE1050 PAE800 Sheet Metal Left Side PAS242 PBS242 Single Phase Filter Network PAE802 Sheet Metal Right Side PAS241...
  • Page 42 Schematic Diagram Section 10...

  • Page 43: Schematic Diagram 50 Hz

    Schematic Diagram Section 10 220/380 50 hz Schematic Diagram...

  • Page 44: Part List 50 Hz

    Parts List Section 11 220/380 50 hz Parts List...
  • Page 45 Parts List Section 11 220/380 50 hz Parts List Part Number Part Number Item Description Item Description SW1200 SW2000 SW1200 SW2000 PAS240 Sheet Metal Top Rectifier Assembly PAE1050 PBE1050 PAE800 Sheet Metal Left Side PAS242 PBS242 Single Phase Filter Network Sheet Metal Right Side PAS241 PBS241...

  • Page 46: Menu Trees

    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 Menu Tree Appendix A PReSeT MeMORY GAS MODULe DATA ReCORDeR These menu trees are for optional modules. Each tree can be brought up on the 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 optional menu trees can be set differently for each weld tool.

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Smartweld sw2000

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