dabotek DT1200i User manual

DABOTEK
Birkedam 10 C - DK 6000 Kolding – Denmark - Tlf.: [phone] - Fax.:[phone]
[e-mail] ; www.dabotek.eu
DABOTEK
DT1200i
P/N 101201
1200 Amp Drawn Arc Stud Welder
OPERATING MANUAL
REVISED MARCH 2009

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:
Underwriters Laboratories Standard UL551
Safety: EN 60974-1 2002
Degree of Enclosure Protection IP 24 in accordance with ISO 60529
This product 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
Technical Contact: Bo Harlev, Product Engineering
DABOTEK
Birkedam 10 C
DK 6000 Kolding
Denmark
Tlf.: [phone]
Fax.:[phone]
[e-mail]
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: [phone] Toll Free: 888 512.7266 Fax: [phone]
Email: [e-mail]
[e-mail]
www.arconweld.com

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 Skin 8
1.5 Fumes and Oxygen Depletion Can Be Dangerous to Your Health 9
1.6 Welding Sparks Can Cause Fire and Explosion 9
1.7 Electric and Magnetic Fields May be Dangerous 9
1.8 Protect Yourself and Others 10
2. PRODUCT DESCRIPTION & INFORMATION 10
2.1 Introduction to The DT1200 and DT1200i 10
2.2 Product Specifications 11
2.3 Safety Standards 11
3. INSTALLATION 11
3.1 Handling 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 Gun Selection 13
3.7 Stud Guns 13
4. OPERATION
4.1 General Description 14
4.2 Design Features 14
4.3 Operational Controls and Settings 14
4.3.1 Circuit Breaker (Power on/Off) 14
4.3.2 Digital Meter on The DT1200i Model 15
4.3.3 Setting the Welding Current & Time 15
4.3.4 Setting the DT1200 (non-Digital) 15
4.3.5 Process for various Stud Welding Positions 15
4.3.6 Process Control Selection (Figure 4.1) 16
4.4 Welding Operation 17
4.4.1 Begin welding utilizing Factory suggested Weld Setpoints 17
4.4.2 Digital Timer and Setting Operation for the DT1200i 17
4.4.3 Discharging the Current after a dry fire (the Stud does not weld) 18
4.4.4 Five-Zones Thermal Protection Control 18

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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 Rear Panel Drawing with part references 31
8.5 Chassis Plate Drawing 1 with part references 32
8.6 Chassis Plate Drawing 2 with part references 33
8.7 Inductor Plate Drawing with part references 34
9. PARTS AND ACCESSORIES
9.1 Replacement Parts 35
9.2 Accessories 37

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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, missing or worn
must be replaced immediately. DABOTEK Welding Equipment LLC or its Authorized Repair
Center will perform warranty Repairs. The Studhorse or any of its parts must not be altered
without the prior written approval of DABOTEK Welding Equipment LLC. Any malfunction
resulting from improper use, faulty maintenance, physical damage, unapproved repair or
alteration, shall be the sole responsibility of the user or owner.Any repair to improperly used or
abused equipment by DABOTEK Welding Equipment LLC will be charged based on DABOTEK’s
applicable hourly labor rate and current replacement part prices.
Manufacturer’s Limited Product Warranty
DABOTEK Welding Equipment’s only warranty is that goods being sold will be free from defects
in materials and workmanship. This express warranty is in lieu of any other warranties, either
expressed or implied, and whether statutory or otherwise, including any implied warranty of
merchantability or fitness for a particular purpose.
The Manufacturer’s written warranty for The DT1200i Stud Welder has been included with your
new machine, 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 an approved Warranty Claim Form. Forms can be downloaded
from the company Web Site at http://www.dabotek.com . The guarantee against
corrosion-related failures can be extended to five-years by completing the Registration Form.
Any equipment that has been modified by any party other than DABOTEK Welding Equipment
LLC, or equipment that has been improperly installed, improperly operated, misused based upon
industry standards, improperly maintained or equipment which has been used for operation
outside of specifications will not be covered under the manufacturer’s warranty. DABOTEK
Welding Equipment shall in no way be liable for any consequential damages.
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.
SAFETY STANDARDS
The DT1200i is designed and built to comply with the following safety standards:
Underwriters Laboratories Standard UL551
Safety EN 60974-1
Degree of Enclosure Protection IP 24 in accordance with ISO 60529
•Protection against full penetration of solid foreign objects of 12.5mm diameter and larger.
•Protection against harmful effects from splashing water against the enclosure from any
direction.

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 cycloaliphatic-epoxides, tetramethylen-oxide and a cationic photo-
initiator (commonly called conformal coating). This protection is incorporated
as certain electrical components and printed circuit boards are produced to
ensure excellent weathering and superior protection against humidity, moisture,
dust, fungus and other contaminants.
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
DABOTEK Welding has taken to increase corrosive atmosphere resistance in
this machine:
Transformer vacuum impregnated twice and dipped an additional time.
Auxiliary transformer 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 coated to protect components from corrosion.
Resistors replaced with porcelain-coated ceramic resistors.
Fan motor totally encapsulated winding coil to withstand corrosive conditions.
Terminal screws coated to prevent electrical arc-overs.
This anti-corrosion process comes with DABOTEK’s five-year manufacturer’s guarantee against
corrosion-related electrical failure within natural operating environments. This warranty begins
the day the machine was shipped from the factory and does not apply to equipment used in
man-made environments that produce chemical residue, dust or airborne debris of man-made
substances, etc.
Because the Seahorse protection is incorporated in the manufacturing process, any circuit
modifications, repairs or component replacement with non-DABOTEK parts will void the
Seahorse guarantee.
Repair centers should contact the factory to obtain replacement parts for this machine.
Customers that intend to submit a warranty request for corrosion related failure should contact
the factory to obtain an RMA number before shipping their welder to the factory for evaluation.

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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 there is a question, ask your supervisor!
1.1 Safety Symbols
Every effort has been made to protect trained operators from injury or unnecessary risk. Certain
symbols are used throughout this manual to call attention to safety-related information and
instruction. The safety symbols in this manual have these meanings:
This symbol indicates Dangerous Situations. When this symbol is used in this manual,
death or serious bodily harm is possible or probable if the corresponding preventative measures
are not taken. Operators 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 without
reading this manual and all safety precautions stated within!
This machine was designed and built with operator safety in mind, but safety begins with you!
Every effort has been made to protect the trained operator from injury. Please become familiar
with the information in this manual to minimize the risk of shock or injury.
STUD WELDING CAN BE HAZARDOUS. ALWAYS PROTECT YOURSELF
AND OTHERS FROM POSSIBLE INJURY OR DEATH. KEEP CHILDREN AWAY.
OPERATORS WHO WEAR A PACEMAKER SHOULD CONSULT WITH THEIR
PHYSICIAN BEFORE OPERATING STUD WELDING EQUIPMENT.
THIS OPERATOR’S MANUAL SHOULD ALWAYS BE KEPT WITH THE STUDHORSE
MACHINE FOR QUICK REFERENCE. ALL SAFETY WARNINGS, SIGNS AND
STICKERS MUST STAY ATTACHED TO THE MACHINE. ALL OPERATORS MUST
BE PROPERLY TRAINED AND PROTECTED BEFORE OPERATING THIS
EQUIPMENT.

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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 electrical (earth) ground.
3. Do not leave an energized machine unattended.
4. Never work in wet clothing, gloves or footwear.
5. Insulate yourself from work and ground using dry insulation. Make certain the insulation
is large enough to cover your full area of physical contact with work and ground.
6. Inspect all system components, protective equipment, cables, connectors and gas lines
prior to operating equipment. Never use cables that are longer than necessary.
7. When testing a live unit, use the one-hand method. Do not put both hands inside of the
unit. Keep one hand free.
8. Disconnect input power conductors from de-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 to the area being welded.
10. Turn OFF welding power source before servicing unless the procedure specifically
requires an energized unit.
11. Never touch the energized stud or gun before discharging the stud to ground.
12. Never use the power source to provide heat for thawing frozen pipes.
1.4 ARC RAYS and EYE PROTECTION
Arc rays can injure eyes and burn skin. Arc flashes are painful.
1. Use a shield with the proper filter and cover plates to protect your eyes from sparks and
the rays of the arc when welding or while observing open arc welding.
2. Use protective clothing specifically intended for work with welding equipment. It should
be made of durable flame-resistant material to provide ample protection from the arc
rays.
3. Protect other nearby workers with suitable, non-flammable screening. Caution other
workers not to watch the arc nor expose themselves to the arc rays or to hot spatter or
metal.

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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 lower the oxygen level causing injury or
death. Be sure the breathing air is safe.
3 Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and
rays of the arcs can react with vapors to form highly toxic and irritating gases.
4 Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel. The
coating must be removed from the area to be welded. Coatings and metals containing
above elements can generate toxic fumes when heated to welding temperature.
1.6 WELDING SPARKS
Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and
explosions.
1. Remove all combustible materials from the work area or cover these materials with a
protective non-flammable tarp. Combustible materials include wood, fabrics, sawdust,
liquid and gas fuels, solvents, paints and coatings, 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
sparks and metal.
1.7 ELECTRIC AND MAGNETIC FIELDS
Electric current flowing through any conductor causes localized Electro-Magnetic Fields
(EMF). Welding and cutting current creates EMF around welding cables and welding machines.
1. Operators having pacemakers should consult their physician before welding. EMF may
interfere with some type of pacemakers.
2. Exposure to EMF may have other health effects, which are unknown.
3. Operators should use the following procedures to minimize exposure to EMF:
a. Route the work cables together. Secure them with electrical tape when possible.
b. Never coil the work cable around any part of your body.
c. Do not place your body between the work cables. Route cables on the same side
of your body.
d. Connect the work cable to the work piece as close as possible to the area being
welded.
e. Keep welding power source and cables as far away from your body as possible.
4. Electromagnetic fields can irrevocable erase magnetic data carriers (computer memory,
credit cards, security ID cards or data storage diskettes).
5. Electromagnetic fields may magnetize and damage watches or similar digital devices.

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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 equipment is essential to
prevent accidents.
1. Always wear safety glasses with side shields in any work area. In conjunction with eye
protection, welding helmets or face shields are also required.
2. Use a face shield fitted with the correct filter cover plates to protect your eyes, face, neck,
and ears from sparks and rays of the arc when operating or observing operations. Warn
bystanders not to watch the arc and not 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 against arc rays and hot sparks or hot metal.
A flameproof apron may also be desirable as protection against radiated heat and
sparks.
4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and
collars should be kept buttoned, and open pockets eliminated from the front of clothing.
2. PRODUCT DESCRIPTION AND INFORMATION
2.1 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
single voltage operating in three-phases.

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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%
79.60%
Height: 17.9”
45.5cm
Width: 10.5”
26.7cm
Approx.
80lbs.
36.3 kg.
Approx.
90lbs.
41.0kg.
Cycle Depth: 19.5”
49.5cm
400V, 480V & 575V SINGLE VOLTAGE * Slow Blow Fuse
*The three-phase supply voltage is connected to a circuit breaker and then to a six-pulse rectifier
circuitry and a radio noise suppression module. The AC voltage is connected to a step-down
transformer to power the welder. The AC welding voltage is first rectified to create a DC welding
current. The control logic measures the welding voltage and welding current. It also makes the
inverter 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 STANDARDS
The DT1200i are designed and manufactured to comply with the following safety standards:
Underwriters Laboratories Standard UL551
Safety EN 60974-1
Degree of Enclosure Protection IP 24 in accordance with ISO 60529
•Protection against full penetration of solid foreign objects of 12.5mm diameter and larger.
•Protection against harmful effects from splashing water against the enclosure from any
direction.
3. INSTALLATION
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.
This section provides detailed instructions for the proper installation of The Studhorse. It is
recommended that these instructions be followed carefully to allow for the best possible
operating environment.

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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.

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 power, the power source must be turned OFF before the unit is
moved.
3.5 Fuses and Circuit Breakers
It is recommended that input fuse sizes be in accordance with the table below:
Input Voltage Welder input
Maximum Amperage
Recommended Fuse
Capacity
400V (CE Version) 24 30A Time Delay (Slo-Blow)
460V-480V 20 30A Time Delay (Slo-Blow)
575V 18 30A Time Delay (Slo-Blow)
Table 2.0
3.6 Output cable connections
The standard supplied output connectors on output the rear panel are female Cam-Lok.
Welders may have been supplied with Tweco type or Dinse (DIX) type if special ordered.
Certain adapters can be supplied as an option. For connection to welding cables. Maximum
recommended length is 50 feet 2/0 gun and ground cable.
3.7 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,
connection, weight, capacity and Duty Cycle. Only guns suitable for drawn arc Stud welding can
be used and are available for 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.
Attach the gun cable to the (-) jack on the power supply and attach the ground clamp to the (+)
jack on the power supply.
There is very little to do when unpacking the Stud Welding gun. The gun should be complete
with all the tools and accessories required for setup, adjustment and maintenance. Guns should
be equipped with the correct chuck, ferrule grip and special accessories for each application.
Operators should consult the Operation/Maintenance Manual from the Stud Gun manufacturer
for complete instructions for safe operation and maintenance.

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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 and capable of welding 5/8-inch full-base weld studs in a
variety of applications. Duty Cycle at 1200 Amps is 6 per minute using 5/8-inch studs. 30 Amp
Slo-Blow fuses provide protection for all input voltages.
4.2 Design Features
The Studhorse power source is designed to be portable and easily transported to provide many
benefits. No crane or special lifting devices are required to move or maintain the machine. The
machine provides Constant Power output with Inverter-smooth arc, incorporating digitally
controlled start/stop with no mechanical contactor. Other features include regulated output,
step-less weld 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 Breaker (Power On/Off)
The Circuit Breaker serves as the main input power switch and located on the control panel
at the rear of the machine. Move the switch lever up to the ON position to start the machine.
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.
After switching on the input power to the machine, the four-digit display shows the
operational mode PA. The display shows the actual Current for three seconds after each
Stud has been welded. The Current setting is displayed as ”(X)XXX” and actual Current is
displayed as ”(X)XXX”.
If display flashes, the machine has exceeded its temperature limits. Wait a few minutes until
the display has stopped flashing, and you can resume welding.

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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 Current and the Time.
When the current value is set to 1200 Amps and a stud is welded, the actual current
delivered (measured value) is displayed after completion of the stud. This current is shown
flashing for 6 seconds. Thereafter, the average between the set value and the measured
value is displayed.
Continued on next page.
For example:
If a value of 1000 Amps is entered into the display and the measured value of 1400 Amps is
flashed after shooting a stud, 1200 Amps is displayed 6 seconds later. If the stud’s height
reduction is correct, the 1200 Amps is maintained. If the height reduction is excessive, the
1400 Amps is reduced to 1000 Amps and measured current 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 the
surface which is welded on and the angle of the stud. Typical variations from stud to stud
may be a low as 1% or 12 Amps.
The Stud Time can be set from 0.05 seconds to 2.00 seconds with 0.01 second accuracy in
.01 second increments using the Time control switch.
4.3.4 Setting the DT1200 (non-Digital)
The DT1200 (non-digital) model is always in ”P” mode, and no other mode is available.
4.3.5 Process for various Stud welding positions
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 Welding
Process Stud Diameter Plate Thickness Position
With a Ceramic 1/4” to 5/8” One (1/4”) Quarter Horizontal
Ferrule Inch Vertical
Overhead
Using Inert Gas 1/4 to ½” One (1/4”) Quarter Horizontal
Inch Only
Short Cycle Less than ½” 16 Gauge Horizontal
Vertical
Overhead

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 TE
RMINALS
3.6
INPUT POWER
CORD
12 FT (3.65m) LONG
3.4
GUN
CONTROL
CONNECTOR
3.7
DIGITAL
CURRENT &
TIMER
METER
4.3.2

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 control circuitry.
The Power-On light on the front panel will be lit.
4. Adjust the Welding Current Control and the Stud Timer Control to fit the type and
diameter of electrode to be used, according to the table below:
4.4.1 Begin welding utilizing Factory suggested Weld Set points
Recommended Current and Time Settings
Stud Size Current Time
Inches Metric (Amps) (Seconds)
1 / 4 (6mm) 450A 0.200
5 /16 (8mm) 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.
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.
After 6 seconds, a steady current value of 1225 A will be displayed, which is the average
between set current and measured current.
The time and current settings will vary with the gun’s lift and plunge settings.
A good weld is characterized by an even ”flash” formation, a shiny, bluish tint to the flash
surface, a slight flow of flash metal into the base material, good flash height, consistant stud
length after the weld and a full circle flash around the stud circumfirence after the weld.

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 wet clothing
before the discharging to ground. The electrical charge in live in the gun for approximately 20
seconds after the trigger is pulled on a ”dry fire”.
Water, moisture and human skin are electrical conductors and complete an electrical circuit to
ground (earth) allowing current to easily flow. Never weld in wet clothing, gloves or footwear.
Always protect yourself from electricity using dry insulation
Never leave an energized machine unattended and always check the condition of cables,
connections and protective gear.
Always keep one hand free when testing an energized machine and unplug equipment before
cleaning or servicing.
Please review and follow all safety precautions in this manual before using the equipment.
4.4.4 Responding to the 5 Zones Thermal 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 depending on
which component is overheated. The following components monitor the internal temperature in
The Studhorse welder:
The 5 Zones of termal protection are incorporated to protect the machine from over temperature
and extend the useful life of the machine. The feature also reduces the risk of costly repairs.
The following zones are protected in your Studhorse power source:
Main Transformer
If overheating occurs, wait 1 minute before restarting.
Main Inductor
If overheating occurs, wait 7-8 minutes before restarting.
Output Capacitor
The Output Capacitor may overheat and shut down the welder. If this occurs, wait
10 minutes before restarting. The temperature sensor will protect the output
capacitor.
Input Capacitor:
Should one phase be lost when welding with three-phase input power, current to
the Input Capacitor could increase causing it to potentially overheat or be
destroyed. Wait 10 minutes before restarting the welder.
Fan Motor:
Some operation with restricted airflow will overheat the fan motor. Wait 10 minutes
before restarting the welder.

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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 help interpret the appearance of the weld flash.

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5.1 Visually Inspecting Welded Studs (continued)