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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 upon receipt of the welder, inspect the shipping box for any damage and notify the 
carrier  of  such  damage  before  accepting  delivery.  Then  inspect 

The  Studhorse

  for  damage 

which  may  have  occurred  in  transit.  After  removing  the  components  from  the  shipping 
container(s),  check  the  container  for  any  loose  parts.  Remove  all  packing  materials. 
 
Visually  check  all  air  passages  of  power  source  for  any  packing  materials  that  may  obstruct 
airflow through the welder. 
 
If the equipment is not being installed immediately, store it in a clean, dry, well-ventilated area 
until installation. 
 

3.2     Selecting a Location 

 
The  location  of  the  power  source  should  be  carefully  selected  to  ensure  satisfactory  and 
dependable  service.  Choose  a  location  relatively  close  to  a  properly  fused  source  of  electrical 
power.  Use care against toppling over if the machine is placed on a tilted surface or plane. 
 
It is important that the machine be located in an open area where air can circulate freely through 
the front and rear openings. If space is at a premium, leave at least 1 foot (300 mm) of clearance 
between the rear of the power source and wall or other obstruction. 
 

3.3     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.  Heavier 2/0 gauge cables can 
be used to extend the distance between the machine and work surface. Standard ground cables 
are 1/0 in diameter with 25 feet maximum length.  Cable lengths can total 50 feet (total primary 
length plus total secondary length) using heavier 2/0 cables.   
 
 

    WARNING! 

  Only qualified personnel should perform this installation. 

  Turn the input power off at the disconnect switch or fuse box before working on 

The 

Studhorse.

 

  Do not touch electrically hot parts. 

 

3.4     Connecting input power 

 
The  standard  factory  installed  input  power  cable  measures  12  ft.    A  longer  power  cable  may 
have been provided as an option if requested. 
 

Summary of Contents for DT1200i

Page 1: ...OTEK 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 2...

Page 2: ...t is in conformity with the requirements of the Low Voltage Directive 73 23 EEC and Machinery directive 89 392 EEC 91 368 EEC 93C 133 04 93 68 EEC Compliance Certified by Goran Hedberg Design Engineer...

Page 3: ...g and Unpacking the Welder 12 3 2 Selecting a Location 12 3 3 Selecting Suitable Supply Cables 12 3 4 Connecting Input Power 12 3 5 Fuse and Circuit Breaker Ratings 13 3 6 Output Connections and Stud...

Page 4: ...the inverter design Figure 8 1 28 8 2 Main Circuit Diagram 29 8 3 Front Panel Drawing with part references 30 8 4 Rear Panel Drawing with part references 31 8 5 Chassis Plate Drawing 1 with part refer...

Page 5: ...e and is limited to defect in materials or workmanship The original purchaser must furnish notice of defect or failure to DABOTEK Welding Equipment or one of DABOTEK s authorized repair centers using...

Page 6: ...mer protected and coated to resist corrosion Output board encapsulated in repair friendly material to eliminate the failures Control board coated to protect against salt water arc over Input board coa...

Page 7: ...tors must take caution in the method and manner of handling or using the machine when this symbol is displayed 1 2 Safety Precautions Do not install operate or repair The Studhorse welding equipment w...

Page 8: ...energized supply line before moving a welding power source 9 Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible...

Page 9: ...oatings paper etc 2 Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire Make certain that such openings are protected from hot spa...

Page 10: ...to expose themselves to the rays of the electric arc or hot metal 3 Wear flameproof type gloves heavy long sleeve shirt cuff less trousers and a welding helmet or cap for hair protection to protect a...

Page 11: ...create the suitable welding characteristics The auxiliary transformer steps down the input voltage to 48V center tapped This transformer powers the cooling fan and the control logic 2 3 SAFETY STANDA...

Page 12: ...l power Use care against toppling over if the machine is placed on a tilted surface or plane It is important that the machine be located in an open area where air can circulate freely through the fron...

Page 13: ...7 Stud Guns There are several manufacturers of Stud welding guns A Stud gun is shaped to fit in the hand in the shape of a handgun and is a semi automatic stud welding tool Guns vary in design connec...

Page 14: ...eld power and time adjustment short circuit protection automatic line voltage protection and 5 zones of thermal protection 4 3 Operational Controls and Settings also refer to Figure 4 1 4 3 1 Circuit...

Page 15: ...t will be 1100 Amps Normally the difference between set and measured is less and only one stud is needed for tuning in process The measured current may fluctuate up to 5 60 Amps 1200 Amps dependent on...

Page 16: ...ER 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...

Page 17: ...m 550A 0 250 3 8 10mm 650A 0 350 1 2 12mm 850A 0 550 5 8 16mm 1200A 0 700 1 If 5 8 inch studs are to be welded set the current timer to 1200 Amps and the timer setting to 0 7 Seconds 2 Shoot weld stud...

Page 18: ...rmal Protection Control The display will begin blinking if any component is overheating The operator must stop welding Studs and allow the power source to cool down This may take 3 minutes or more dep...

Page 19: ...uide 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 sho...

Page 20: ...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: ...ing parts other than the fan in the power source basic preventive maintenance only involves keeping the welder clean and free from metallic dust Periodically you should ask your Authorized Service Cen...

Page 25: ...educe duty cycle 1b Make sure that intake and exhaust vents are not blocked In heavy dust areas clean unit out once per month with compressed air B Circuit breaker trips 1 Over voltage or spikes 2 Inc...

Page 26: ...air 1 Clean surface 2 Read gun manual for procedure 3 Read gun manual for procedure G Display has fluctuating amperage levels H Display is flashing 1 Unit is self calibrating and will complete calibra...

Page 27: ...of type X to be allowed to be connected between phases and also to comply with the European community CE norms The type X capacitors are connected to a common point making it a virtual neutral This p...

Page 28: ...ter 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 AU...

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Page 35: ...001 FAN ASSY 15 011216 001 FAN BLADE 17 011220 002 INDUCTOR OUTPUT 18 011230 001 INDUCTOR MAIN w PTC 19 011241 001 INDUCTOR COMMUTATING FRONT 20 011251 001 INDUCTOR COMMUTATING REAR 21 011272 001 TRAN...

Page 36: ...1 CLAMP OUTPUT CAPACITOR 65 017102 003 CLAMP INPUT CAPACITOR w PTC BOARD 66 017110 001 BRACKET MOUNTING TRANSFORMER 67 018500 001 JACK OUTPUT DINSE FOR PLASTIC PANEL 68 018500 005 JACK OUTPUT DINSE FO...

Page 37: ...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 CABL...

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