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- DT1200i
- Operating Manual
Dabotek DT1200i Operating Manual
Summary of DT1200i
Page 1
Dabotek 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 2009.
Page 2: Declaration Of Conformity
Declaration of conformity manufacturer for dabotek name: arcon welding equipment, llc manufacturer’s address: 2203 northwood drive, building 10 salisbury, maryland 21801 usa declares that the product: product name: dt1200i model number 101200-xxx 101201-xxx conforms to the following standards: under...
Page 3
3 dt1200i operations and service manual table of contents general information user responsibility 5 limited warranty 5 safety standards 5 corrosion protection 6 1. Safety 7 1.1 safety symbols 7 1.2 safety precautions 7 1.3 electric shock can injure or kill 8 1.4 arc rays can injure eyes and burn ski...
Page 4
4 5. Visual inspection 5.1 visually inspection welded studs 19 6. Maintenance and repair 24 7. Troubleshooting guide 25 8. Electrical specifications & diagrams 27 8.1 the principles of the inverter design (figure 8.1) 28 8.2 main circuit diagram 29 8.3 front panel drawing with part references 30 8.4...
Page 5: General
5 general information user responsibility dabotek welding warrants that the dt1200i will perform in accordance with the product description in this manual. The factory warranty will be null and void should the user attempt to operate the studhorse after it has malfunctioned. Parts that are broken, m...
Page 6
6 please review all safety infomation in section 1 very carefully before operating the machine. This machine is protected against corrosion dabotek’s time-proven seahorse manufacturing process protects electrical components prone to failure from corrosion by design and using a compound containing cy...
Page 7: 1. Safety
7 1. Safety safety is eveyone’s responsibility. Dabotek designs every machine with safety in mind, and a safe work environment depends largely on you. Do not install, operate, or repair this equipment without carefully reading this manual and observing all of the safety precautions mentioned. If the...
Page 8
8 1.3 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 el...
Page 9
9 1.5 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. 1. When working in a confined space always have trained support personnel nearby. Welding fumes and gases can displace air and ...
Page 10
10 1.8 protect yourself and others! Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (uv) and other radiation and may injure skin and eyes. Hot metal can cause burns. Training in the proper use of welding processes and equipm...
Page 11: 3. Installation
11 2.2 product specifications stud welding open input amperes at physical weight primary input welding current range (amps) circuit voltage rated load output* (50/60 hz) kw efficiency dimensions net ship 400v 480v 575v three phase 1200a @6% duty 300- 1200 80 max 35 ±10% 30 ±10% 25 ±10% 23.8 ±20% 79....
Page 12
12 3.1 handling and unpacking the welder since the dt1200i and machines weigh approximately 90 pounds in the shipping carton, no fork lift or crane is necessary to move the machine. The shipping carton has built-in reinforced handles to enable two people to easily transport the machine. Immediately ...
Page 13
13 the primary cable supplied with the power source has 4 conductors. When connecting an attachment plug or hard wiring to an electrical service box, connect the green/yellow wire to the ground. The remaining 3 conductors can be connected to the phases in any order. Once connected to the primary pow...
Page 14: 4. Operation
14 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 ...
Page 15
15 4.3.3 setting the welding current and time the current is controlled by using a microprocessor with an auto tuning function. Pressing the push-button switch on the front panel toggles the display presentation between current and time. There are separate (potentiometer) controls for setting the cu...
Page 16
16 4.3.6 process control selection figure 4.1 power 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 connector 3.7 digital current & timer meter 4....
Page 17
17 4.4 welding operation 1. All secondary outputs must be connected to output terminals of the power source 2. After the primary input connections have been made, close the main wall disconnect switch or circuit breaker. 3. Put the primary power selector in the on position. This will turn on the con...
Page 18
18 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 ...
Page 19: 5. Visual Inspection
19 5. Visual inspection 5.1 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 he...
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20 5.1 visually inspecting welded studs (continued ).
Page 21
21 5.1 visually inspecting welded studs (continued).
Page 22
22 5.1 visually inspecting welded studs (continued).
Page 23
23 5.1 visually inspecting welded studs (continued ).
Page 24
24 6. Maintenance & repair warning! Please see chapter 1 regarding safety • turn the input power off before working on any dabotek stud welder. • do not touch electrically live parts or electrode with your skin or wet clothing • insulate yourself from work and ground • always wear dry insulating glo...
Page 25
25 7. Trouble shooting guide warning – please observe all safety precautions trouble probable cause remedy a. Fan rotates, no welding current. A2. Unit shut down while welding, fan runs, display flashing 1. Gun remote cable not plugged in 2. Gun remote cable is defective. 3. Trigger was pulled withi...
Page 26
26 trouble probable cause remedy f. “e10” flashing on display 1. No arc initiated when trigger was pulled between stud and work piece. 2. Unit was dry fired, e.G. The gun with stud was not pressed against grounded piece of metal 3. Trigger was pulled with gun in the air 1. Clean surface 2 . Read gun...
Page 27
27 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 ...
Page 28
28 8.1 the principles of the inverter 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 auxiliary transformer welding output.
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Page 35: Stud Welder
35 stud welder replacement parts list part dwg number description ref# 011260-011 transformer, main w/ptc, 400v 1 011260-013 transformer, main w/ptc, 480v 1 010440-001 power cable assy, 10awg, 12.5ft ce 2 010490-003 chassis, main 3 010520-002 panel, rear - metal 4,5,46 010511-012 panel, upper rear, ...
Page 36
36 016010-001 capacitor, input 41 011551-001 capacitor, input w/ ptc 42 015101-001 capacitor, output w/ ptc 43 016020-001 capacitor, output 44 010560-002 louver, front 45 010512-002 louver, rear 46 016920-001 relay, for stud gun control board 47 016202-001 resistor, surge, 0.15 ohm 48 016330-001 cir...
Page 37: Stud Welder
37 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 wa...