SW1200 & SW2000

img-1The Smart Weld™ series of Stud Welders brings many advancements to the art of stud welding. These power supplies are loaded with standard and optional features so you can tailor this welder to meet your specific needs.

Standard Features

Maintenance Tracker

maintenance-trackerThis feature counts the actual number of welds. The user can set an alert or notification point (see Alert Set, in this case 3,000). When the number of welds equals the alert point, the display panel flashes that maintenance is due. For example, you want to perform preventative maintenance on the welder every 100,000 welds. The alert point gets programmed to 100,000. When the weld count (See Alert Count, currently 0) reaches 100,000, the display flashes “Maintenance.” The count point can then be reset to zero and the counting begins again. 

Programmable Pilot Arc

programmable-pilot-arcThe pilot arc is the part of the weld sequence which starts the arc. Typically, this setting does not need to be adjusted. However, there are some special circumstances in which it is beneficial to adjust this parameter. For example, when doing short arc (short cycle) stud welding, it is helpful to turn the pilot arc completely off. Many competitive units don’t even offer a pilot arc, let alone a programmable one.

Hammer Mode

Hammer mode assists in penetrating rust, mill scale or even paint. We recommend that this feature be used in conjunction with Hammer Weld™ studs. It works this way: The power supply looks for a good ground path, if none is found the power supply causes the weld tool to lift and plunge (hammer). The sharp point on the Hammer weld stud begins to penetrate the surface. The cycle begins again. When the welder does detect a suitable ground path, the arc is initiated. This feature can be turned off or programmed for as many as 15 hammer cycles.

Feature Locking

feature-lockingEliminates concerns about unwanted parameter adjustments. This feature can lock all, some, or none of the Smart Weld features. To access a locked feature, a password must be entered. This is great for maintaining ISO implementation. This also can eliminate disagreements between operators and/or shifts. Since the unit is locked, it prevents unauthorized adjustments.

Foreign Languages

This unit is NAFTA ready. It is programmed in English, French, and Spanish (shown in Spanish on the left). We recognize that our customer base is growing and that many operators’ first language will not be English. Changing the language of all menus is quick and easy.

Standard Features

Multi-Weld Tool (up to 4)

multi-weld-toolPossibly the most popular feature of the Smart Weld series is the ability to expand with multiple output ports.  This is beneficial when there is a need for multiple stud sizes that a single operator must install.  Rather than waste valuable time switching tooling to weld different size studs, the operator can simply pick up a second weld tool and weld instantaneously without worrying about setup or adjusting weld parameters.

Another scenario in which multiple outputs are useful is in the multiple line manufacturing set up.  Say there are three production lines making boxes.  A couple of studs go onto the inside of the boxes.  Rather than purchase three stud welders, one for each line, a three output Smart Weld can suffice.  Run a weld tool to each line.

The multi-weld tool setup can save capital expenditures as well as save valuable floor space.

Memory Presets

The memory preset module can store ALL information related to a weld schedule.  This includes the programmable pilot arc, hammer mode, gas mode, and SPC limits.  Each weld output has eight preset locations.  That is a total of 32 weld schedules for a four output power supply.  A memory location is programmed just like most car radios, so it is fast and simple.  To recall a weld schedule, just press the button and all parameters are recalled instantly.

Data Recorder

The data recorder performs two primary functions:

  • Transmits weld results via serial cable
  • Holds statistical process control (SPC) limits

When the data recorder module is installed, the power supply transmits data to a data recording device.  The data output is set up information such as output number, desired weld time and current, and a time stamp.  Key data output is the actual weld results and any error information.  This data can be captured by any device capable of reading serial ASCII data.  Devices might include: printers, laptops, and palm pilots.

The data recorder module also allows a company to program SPC limits into the power supply.  This can be helpful for ISO 9000 style programs.  For example, the weld engineering determines that the ideal weld current for a particular weld is 500 Amps.  However, in the real world, there are variations in every process, so weld engineering will tolerate welds in the range of 470-550 Amps.  These limits are entered into the unit for a particular weld output port (unique values can be entered for each of the multi-weld tool output ports).  Limits are also saved in the memory module.  During the course of welding, if a weld drifts outside the SPC limits defined, then an error is generated.

Integrated Gas Arc

This allows for welding using shielding gas instead of flux and ferrule combination.  Gas arc is required for welding alloys such as aluminum and magnesium.  The power supply microprocessor precisely controls the gas welding sequence for maximum repeatability.  Pre-flow and post-flow values are controlled to 0.01 seconds.  The weld will not start until pre-flow time has properly elapsed so each weld will be properly purged.  Because gas is shut off after post flow, the valuable shielding gas is not wasted.


The Smart Weld series welders have been designed with auto-feed in mind.  The power supply directly controls the weld tool and the feeder bowl.  This means lighter equipment, easier setup and easier troubleshooting should problems arise.  This can work with handheld, production, or robotic applications.  The unit can be set for request-driven feeds (robots with different weld tools) or for feed after the weld so a stud is delivered to the weld tool immediately after ground is broken.

High Level Control

This allows an external device to control most functions of the welder via a port on the welder.  There are two different schemes supported:

  • Simple I/O scheme using discrete I/O lines
  • Powerful control scheme using RS-232 communication

The discrete I/O scheme is appropriate for simple production jobs. The welder can accept feed and weld requests to the first 2 weld tools.  The welder responds with feed and weld complete signals.  A ground detect signal is also provided.  This scenario is adequate for many automation applications.

Using RS-232, a robot or PLC can achieve sophisticated control of the welder.  This can include changing weld schedules, identifying specific errors and collecting weld quality data.