Related Manuals for dabotek DT1200i
Summary of Contents for dabotek DT1200i
- Page 1 DABOTEK DT1200i P/N 101201 1200 Amp Drawn Arc Stud Welder OPERATING MANUAL REVISED MARCH 2009 DABOTEK Birkedam 10 C - DK 6000 Kolding – Denmark - Tlf.: +45 7550 5666 - Fax.:+45 7550 4795 sales@dabotek.com www.dabotek.eu...
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Page 2: Declaration Of Conformity
Tlf.: +45 7550 5666 Fax.:+45 7550 4795 sales@dabotek.com www.dabotek.com For further details please contact the manufactor for DABOTEK : ARCON Welding Equipment LLC 2203 Northwood Drive, #10 Salisbury, Maryland 21801 USA Tel: 410 572.6000 Toll Free: 888 512.7266 Fax: 410 572.6027 Email: sales@arconweld.com... -
Page 3: Table Of Contents
4.3.6 Process Control Selection (Figure 4.1) 4.4 Welding Operation 4.4.1 Begin welding utilizing Factory suggested Weld Setpoints 4.4.2 Digital Timer and Setting Operation for the DT1200i 4.4.3 Discharging the Current after a dry fire (the Stud does not weld) 4.4.4 Five-Zones Thermal Protection Control... - Page 4 5. VISUAL INSPECTION 5.1 Visually inspection welded Studs 6. MAINTENANCE AND REPAIR 7. TROUBLESHOOTING GUIDE 8. ELECTRICAL SPECIFICATIONS & DIAGRAMS 8.1 The principles of the inverter design (Figure 8.1) 8.2 Main Circuit Diagram 8.3 Front Panel Drawing with part references 8.4 Rear Panel Drawing with part references 8.5 Chassis Plate Drawing 1 with part references 8.6 Chassis Plate Drawing 2 with part references...
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Page 5: General Information
DABOTEK Welding Equipment reserves the right to make engineering and/or part changes at any time, without notice, as improvements in quality or design are made. Owners and operators of The DT1200i should access the company Web site listed above to keep up-to-date with offerings, applications and technical suggestions. -
Page 6: Corrosion Protection
The Seahorse process used in this machine was developed and tested on oilrigs in the North Sea decades ago. This protection enhances reliability, prolongs component life and adds value to all of DABOTEK’s rugged line of portable welding power sources. Listed below are some of the steps... -
Page 7: Safety
1. SAFETY Safety is eveyone’s responsibility. DABOTEK designs every machine with safety in mind, and a Do not install, operate, or repair this safe work environment depends largely on you. equipment without carefully reading this manual and observing all of the safety precautions mentioned. -
Page 8: Electric Shock Can Injure Or Kill
ELECTRIC SHOCK Precautionary measures must be taken to provide maximum protection against electrical shock. Electric shock can injure or Kill WARNING 1. Do not touch live or energized electrical parts or store metallic objects near power. 2. Ground the work or metal to be welded to a good electrical (earth) ground. 3. -
Page 9: Fumes And Oxygen Depletion Can Be Dangerous To Your Health
FUMES and OXYGEN DEPLETION Only weld in areas or rooms where adequate ventilation of weld gases is possible, and where there are not fire, smoke or explosion hazards. When working in a confined space always have trained support personnel nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. -
Page 10: Protect Yourself And Others
2. PRODUCT DESCRIPTION AND INFORMATION INTRODUCTION TO THE DT1200I The DT1200i machines are portable drawn arc Stud welders using an inverter-type power supply to generate the output power. Both machines are currently available in the following models: 400V single voltage for European industry, 480V single voltage operating in three-phases; 575V... -
Page 11: Product Specifications
The auxiliary transformer steps down the input voltage to 48V center tapped. This transformer powers the cooling fan and the control logic. SAFETY STANDARDS The DT1200i are designed and manufactured to comply with the following safety standards: Underwriters Laboratories Standard UL551 Safety... -
Page 12: Handling And Unpacking The Welder
Selecting Suitable Supply Cables The standard power input cable for The DT1200i welder is a high quality #14 Gauge cable that is 12.5 feet long. The secondary cables that connect the Stud gun to the power source vary with manufacturers, but is normally 1/0 diameter and 8 feet in length. -
Page 13: Fuse And Circuit Breaker Ratings
Short Cycle, Standard Duty and Heavy-Duty use. The pin configuration of the gun must be compatible with The DT1200i. Units come standard with a 4-pin panel mounted control connector for the firing gun. The pistol grip switch initiates the stud current through the welding cables and, at the same time, powers the solenoid in the gun so that it retracts. -
Page 14: Operation
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. -
Page 15: Digital Meter On The Dt1200I Model
Drawn Arc Stud Welding allows weldable 1/8” to 5/8” diameter Studs made of non-alloyed, alloyed, stainless and heat-resistant steels to suitable base materials. The following is a guide for welding positions using the DT1200 and DT1200i machines: Stud Welding Minimum... -
Page 16: Process Control Selection (Figure 4.1)
4.3.6 Process Control Selection DIGITAL CURRENT & TIMER METER 4.3.2 POWER ON INDICATOR 4.3.1 CONTROL 4.4.4 CONNECTOR CIRCUIT BREAKER (POWER ON/OFF) 4.3.1 STUD TIMER CONTROL 4.3.3 WELDING 4.4.1 CURRENT INPUT POWER CONTROL CORD 4.3.3 12 FT (3.65m) LONG 4.4.1 OUTPUT TERMINALS FIGURE 4.1... -
Page 17: Welding Operation
0.7 Seconds. 2. Shoot (weld) stud. 4.4.2 Digital Timer and Setting Operation for The DT1200i Depending on the length of your welding and gun cables, the measured current may be 1250A. This number will be displayed on the current display. -
Page 18: Discharging The Current After A Dry Fire (The Stud Does Not Weld)
4.4.3 Discharging the Current after a test fire (the Stud is not welded) WARNING – ELECTRIC SHOCK CAN INJURE OR KILL! The gun and ground circuits are electrically charged or ”hot” when The Studhorse is switched on and the gun trigger is depressed. Do not touch these ”hot” parts with bare skin or wet clothing before the discharging to ground. -
Page 19: Visual Inspection
5. VISUAL INSPECTION Visually Inspecting Welded Studs Use this guide 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 should used this guide to help interpret the appearance of the weld flash. - Page 20 Visually Inspecting Welded Studs (continued...
- Page 21 Visually Inspecting Welded Studs (continued)
- Page 22 Visually Inspecting Welded Studs (continued)
- Page 23 Visually Inspecting Welded Studs (continued...
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Page 24: Maintenance And Repair
Do not permit untrained persons to inspect, clean, or repair The Studhorse. Please call the factory for the location of the Authorized DABOTEK Service Center nearest you. Since there are no moving parts other than the fan in the power source, basic preventive maintenance only involves keeping the welder clean and free from metallic dust. -
Page 25: Troubleshooting Guide
7. TROUBLE SHOOTING GUIDE WARNING – PLEASE OBSERVE ALL SAFETY PRECAUTIONS TROUBLE PROBABLE CAUSE REMEDY A. Fan rotates, no welding 1. Gun Remote Cable not 1. Plug in Gun Remote Cable current. plugged in and recheck unit. 2. Gun Remote Cable is defective. - Page 26 TROUBLE PROBABLE CAUSE REMEDY F. “E10” flashing on display 1. No arc initiated when trigger 1. Clean surface was pulled between stud and work piece. 2. Unit was dry fired, e.g. the 2. Read gun manual for gun with stud was not pressed procedure.
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Page 27: Electrical Specifications & Diagrams
8. ELECTRICAL SPECIFICATIONS & DIAGRAMS Circuit breaker The 3 phase elecric input power is connected to circuit breaker (K). CF Assembly The CF assembly has three functions: a six-pulse rectifier, suppression of elector-magnetic interference (EMI) and suppression of input voltage surges from the power lines. Rectifier The input rectifier consists of the power diodes CR1 to CR6. -
Page 28: The Principles Of The Inverter Design (Figure 8.1)
8.1 The Principles of the Inverter Design The inverter function is perhaps easiest understood using the simplified block diagram below. AC INPUT MAIN RECTIFIER INVERTER TRANSFORMER RECTIFIER CONTROL OUTPUT BOARD FILTER AUXILIARY TRANSFORMER WELDING OUTPUT FIGURE... -
Page 29: Main Circuit Diagram
8.2 MAIN CIRCUIT DIAGRAM... -
Page 30: Front Panel Drawing With Part References
8.3 FRONT PANEL DRAWING WITH PART NUMBER REFERENCE... -
Page 31: Rear Panel Drawing With Part References
8.4 REAR PANEL DRAWING WITH PART NUMBER REFERENCE 1 of 1... -
Page 32: Chassis Plate Drawing 1 With Part References
8.5 ASSEMBLY DRAWING 1 WITH PART NUMBER REFERENCE... -
Page 33: Chassis Plate Drawing 2 With Part References
8.6 ASSEMBLY DRAWING 2 WITH PART NUMBER REFERENCE... -
Page 34: Inductor Plate Drawing With Part References
8.7 INDUCTOR PLATE DRAWING WITH PART NUMBER REFERENCE... -
Page 35: Replacement Parts
STUD WELDER REPLACEMENT PARTS LIST PART NUMBER DESCRIPTION REF# 011260-011 TRANSFORMER, MAIN w/PTC, 400V 011260-013 TRANSFORMER, MAIN w/PTC, 480V 010440-001 POWER CABLE ASSY, 10AWG, 12.5FT CE 010490-003 CHASSIS, MAIN 010520-002 PANEL, REAR - METAL 4,5,46 010511-012 PANEL, UPPER REAR, PLASTIC 010513-001 PANEL, LOWER REAR, PLASTIC 010551-013... - Page 36 016010-001 CAPACITOR, INPUT 011551-001 CAPACITOR, INPUT w/ PTC 015101-001 CAPACITOR, OUTPUT w/ PTC 016020-001 CAPACITOR, OUTPUT 010560-002 LOUVER, FRONT 010512-002 LOUVER, REAR 016920-001 RELAY, FOR STUD GUN CONTROL BOARD 016202-001 RESISTOR, SURGE, 0.15 OHM 016330-001 CIRCUIT BREAKER 018401-001 BRACKET, MOUNTING, FOR CIRCUIT BREAKER 016331-001 SPACER FOR CIRCUIT BREAKER 016611-001...
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Page 37: Accessories
STUD WELDER ACCESSORIES PART NUMBER DESCRIPTION WA1200-001 STUD GUN, MEDIUM DUTY WA1200-011 EXTENSION CABLE FOR STUD GUN, 32FT, 2/0, 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 CABLE WAP1200-021...