Taylor 1200E Operating Manual
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Taylor 1200E Operating Manual

Multi gun drawn arc controllers
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TAYLOR STUDWELDING
SYSTEMS LIMITED
OPERATING GUIDE
FOR TYPE
1200E & 1600E
MULTI GUN DRAWN ARC
CONTROLLERS
2, 3 & 4 GUN MODELS
V-21A
A TAYLORMADE DRAWN ARC STUDWELDING SYSTEM TO WELD UP TO 16mm REDUCED BASE STUDS

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Summary of Contents for Taylor 1200E

  • Page 1 TAYLOR STUDWELDING SYSTEMS LIMITED OPERATING GUIDE FOR TYPE 1200E & 1600E MULTI GUN DRAWN ARC CONTROLLERS 2, 3 & 4 GUN MODELS V-21A A TAYLORMADE DRAWN ARC STUDWELDING SYSTEM TO WELD UP TO 16mm REDUCED BASE STUDS...
  • Page 2 INDEX PAGE No. CONTENT USEFUL INFORMATION. IMPORTANT SAFETY INFORMATION. INTRODUCTION TO STUDWELDING. GUIDE TO EXTERNAL FEATURES. SETTING UP AND WELDING. WELDING TIME AND CURRENT SETTINGS. VISUAL WELD INSPECTION. WELD TESTING. STUDWELDING TECHNIQUES. PARTS LIST & EXPLODED DIAGRAMS. PCB’s - LED GUIDE CIRCUIT SCHEMATICS ACCESSORIES.

  • Page 3: Useful Information

    USEFUL INFORMATION MANUFACTURERS DETAILS TAYLOR STUDWELDING SYSTEMS LIMITED COMMERCIAL ROAD DEWSBURY WEST YORKSHIRE WF13 2BD ENGLAND TELEPHONE +44 (0)1924 452123 FACSIMILE +44 (0)1924 430059 email sales@taylor-studwelding.com www.taylor-studwelding.com SALES DIRECT TEL +44 (0)1924 487703 TECHNICAL HELPLINE : +44 (0)1924 487701 You may wish to record the details of your controller below as this information will help with any technical assistance you may require: CONTROLLER SERIAL No.

  • Page 4: Further Information

    ISOLATING THE CONTROLLER FROM THE MAINS ELECTRICAL SUPPLY. NEVER OBSTRUCT THE UNDERSIDE, FRONT OR REAR PANELS AS THIS MAY CAUSE THE UNIT TO OVERHEAT DURING OPERATION. Taylor Studwelding Systems Limited reserves the right to amend the contents of this guide without notification. V-21A...

  • Page 5: Important Safety Information

    IMPORTANT SAFETY INFORMATION ! PROTECT YOURSELF AND OTHERS ! Read and understand these safety notes. 1. ELECTRICAL No portion of the outer cover of the welding controller should be removed by anyone other than suitably qualified personnel and never whilst mains power is connected. ALWAYS DISCONNECT THE MAINS LEAD BEFORE ATTEMPTING ANY MAINTENANCE.

  • Page 6: Installation

    During welding operations, intense magnetic and electrical fields are unavoidably produced which may interfere with other sensitive Electronic equipment. All Taylor Studwelding equipment is designed, manufactured and tested to conform the current appropriate European standards and directives regarding electromagnetic emissions and immunity and as such is safe to use in any normal industrial environment.
  • Page 7 INTRODUCTION TO STUDWELDING The Taylor Studwelding 1200E/1600E Drawn Arc Multi Gun controller when matched with up to 4 appropriate pistols and earth cables is intended for precision stud welding up to 16/20 mm diameter reduced base studs. The controller is easily transportable and has been designed to operate with a minimum amount of maintenance.

  • Page 8: Front Panel

    GUIDE TO EXTERNAL FEATURES FRONT PANEL GUIDING HANDLE - ! NOT FOR LIFTING ! MAINS ON/OFF SWITCH PISTOL WELDING CONNECTION SOCKET (MODEL DEPENDENT, UP TO 4) PISTOL CONTROL CONNECTION SOCKET (MODEL DEPENDENT, UP TO 4) WELDING EARTH CONNECTION SOCKET (MODEL DEPENDENT, UP TO 4) ADVISORY STICKER (NOT FOR LIFTING) CONTROL PANEL (SEE PAGE 9) SHIELDING GAS OUTLET SOCKET...

  • Page 9: Control Panel

    GUIDE TO EXTERNAL FEATURES CONTROL PANEL WELD COUNTER (NON-RESETTABLE) PUSHBUTTON (WELD CURRENT SETTING/CURRENT READBACK) PUSHBUTTON (WELD TIME SETTING/ERROR CODE READBACK) DISPLAY WINDOW (WELD CURRENT SET/CURRENT READBACK) DISPLAY WINDOW (WELD TIME SET/SHIELDING GAS PURGE TIME SET/ERROR CODE READBACK) ADJUSTER KNOB PUSHBUTTON (SHIELDING GAS PURGE SETTING/PARAMETER READBACK) INDICATOR (SHIELDING GAS PURGE ACTIVATED) INDICATOR (STUD TO PLATE CONTACT) INDICATOR (PISTOL TRIGGER ACTIVATED (1 TO 4, MODEL DEPENDENT))
  • Page 10 GUIDE TO EXTERNAL FEATURES BACK PANEL LIFTING EYEBOLTS VENTILLATION GRILLES - ! DO NOT OBSTRUCT ! RATING/SERIAL PLATE REAR CASTORS (FIXED TYPE. NO BRAKE) SHIELDING GAS INLET SOCKET 3 PHASE MAINS CABLE INLET GLAND (CABLE NOT SHOWN). V-21A...
  • Page 11 SETTING UP AND WELDING Set up the control unit at the place of work, ensuring that the mains switch is in the OFF position. Plug the controller into a suitable three phase AC supply with a 63A motor rated fuse/breaker. Plug the welding earth cables into the controller.
  • Page 12 SETTING UP AND WELDING Switch the controller ON by turning the mains switch clockwise through 90°. The ventilation fans will start, the display will illuminate and carry out a start up diagnostic routine. This will take approx’ 6 seconds at the end of which the display will indicate the current settings of the last pistol used.
  • Page 13 SETTING UP AND WELDING SET WELD TIME Press and hold the weld time setting pushbutton (3). Turn the adjuster knob (6) until the required time is displayed in the display window (5). The time is adjustable between 20 and 2000ms in 5ms increments up to 100ms and 10ms increments thereafter.
  • Page 14 SETTING UP AND WELDING Place the pistol perpendicular to the work piece with the stud touching down at the desired location to be welded. Press down on the pistol until the ceramic ferrule rests firmly on the work piece. Press the trigger to initiate the weld sequence.
  • Page 15 WELDING TIME AND CURRENT SETTINGS STUD ACTUAL WELD WELD This page is intended as a guide to setting your TYPE DIAMETER CURRENT TIME machine. (mm) (ms) A set of basic formulae as defined by the British Standard BS EN ISO 14555:2014 (European Standard EN ISO 14555:2014) Annex A.2.7.2.2 and Annex A.2.7.2.4 may be used to calculate the current and time settings to weld any stud.
  • Page 16 VISUAL WELD INSPECTION This page will help you to recognise a poor weld when you see one and give some of the possible explanations as to how it may have occurred. Your test welds should look like the first example diagram in the series and once you transfer to the actual job, periodic checks should be made to ensure that your welding is consistently good.
  • Page 17 VISUAL WELD INSPECTION EXAMPLE 4 PROBLEM : Insufficient stud protrusion set on the pistol.  REMEDY : Adjust stud protrusion to correct setting (refer to your pistol setup guide). EXAMPLE 5 PROBLEM : Poor alignment i.e. stud is not perpendicular to the workpiece. REMEDY : Hold the pistol perpendicular to the work-piece (see page 14).
  • Page 18 WELD TESTING There are two factors which should receive special attention in establishing visually whether or not a stud weld is sound. These are : • The length after weld (L.A.W.) of the stud should be correct. That is to say that a stud which is intended to be 50 mm long after welding, should be correct within the tolerances specified for that particular stud.

  • Page 19: Non Destructive Testing

    WELD TESTING 2. NON DESTRUCTIVE TESTING. Generally the most practical way of testing threaded stud welds, without destroying the stud, is with the use of proof tests. A torque wrench is particularly useful for this purpose. Below and overleaf are some tables which you may find useful. However, it must be noted that : •...
  • Page 20 WELD TESTING Stud loads - Full Base Drawn Arc Studs (kN) Mild Steel Mild Steel Mild Steel Stainless Stainless Stainless Steel Steel Steel Thread Yield Safe Yield Safe M5 x 0.8 M6 x 1.0 10.6 M8 x 1.25 15.2 12.3 19.6 12.7 10.1...
  • Page 21 STUDWELDING TECHNIQUES The operating instructions given previously in this guide apply to the majority of general applications where it is possible to use the pistol in the down hand position and with standard cable lengths. For many applications these conditions do not apply and the following notes will give some guidance as to the methods used to obtain satisfactory results for a variety of applications.
  • Page 22 STUDWELDING TECHNIQUES 5. WELDING STUDS LESS THAN 25 mm LONG USING FERRULES. As we have seen previously, the stud is held in a recess in the chuck and must be long enough to allow us to set the correct protrusion. A standard chuck has a recess 12 mm deep and ferrules vary in length up to 13.5 mm high.
  • Page 23 STUDWELDING TECHNIQUES 9. WELDING CLOSE TO CORNERS, FLANGES AND OTHER OBSTACLES. When welding close to the edge of a plate, in / on a corner, on long strips of narrow plate etc. An effect known as "arc-blow" occasionally will produce an uneven fillet, in such a fillet, most of the material is blown to one side of the stud.

  • Page 24: Parts List & Exploded Diagram

    PARTS LIST & EXPLODED DIAGRAM ITEM No. OFF PART No. DESCRIPTION 81-120-032 HANDLE - ! NOT FOR LIFTING ! 81-106-260 ADVISORY STICKER 81-106-128 EYEBOLT 81-106-253 TOP COVER 81-106-252 SIDE PANEL 81-106-265 STICKER (1200 MODEL) 81-106-280 STICKER (1600 MODEL) 81-106-251 SIDE PANEL V-21A...
  • Page 25 PARTS LIST & EXPLODED DIAGRAM SEE PAGE 29 FOR A MORE DETAILED BREAKDOWN SEE PAGE 33 FOR A MORE OF THE CONTROL SEE PAGE 32 FOR A MORE DETAILED BREAKDOWN HOUSING ASSEMBLY DETAILED BREAKDOWN OF THE BACK PANEL OF THE SPLITTER ASSEMBLY ASSEMBLIES SEE PAGE 31 FOR A MORE...
  • Page 26 PARTS LIST & EXPLODED DIAGRAM 2 GUN MODEL 3 GUN MODEL 4 GUN MODEL SEE PAGE 27 FOR PARTS EXPLOSION FOR THESE PANELS. * QUANTITIES FOR EACH MODEL ARE AS SHOWN IN VIEWS ABOVE. ITEM No. OFF PART No. DESCRIPTION 81-106-249 SINGLE BLANKING SUB-PANEL 81-106-250...
  • Page 27 PARTS LIST & EXPLODED DIAGRAM 81-106-248 81-106-250 * PART QUANTITIES ARE AS SHOWN IN BREAKDOWN FOR EACH INDIVIDUAL PANEL ITEM No. OFF PART No. DESCRIPTION 81-106-248 SINGLE PISTOL SUB-PANEL 81-106-255 PISTOL NUMBER DECAL SET (1 2 3 4) PFX-CSS-B06-BUL SHIELDING GAS OUTLET SOCKET 70-102-025 CONTROL SOCKET 81-106-031...
  • Page 28 PARTS LIST & EXPLODED DIAGRAM ITEM No. OFF PART No. DESCRIPTION 81-106-259 DECAL 81-106-240 BASEPLATE 81-106-236 1200A WELDING TRANSFORMER 81-106-200 1600A WELDING TRANSFORMER 81-106-289 TRANSFORMER MOUNT PLATE (1600 MODEL ONLY) 81-106-218 SNUBBER 81-106-195 SHUNT 81-106-241 SUPPORT TUBE 81-106-009 CASTOR (SWIVEL & BRAKE) 81-106-011 CASTOR (FIXED, NO BRAKE) 81-120-056...
  • Page 29 PARTS LIST & EXPLODED DIAGRAM SEE PAGE 30 FOR DETAILED OPTIONS AND PARTS LISTING FOR TERMINAL/FUSE ASSEMBLY * QUANTITY DEPENDENT ON CONTROLLER MODEL 13,14 ITEM No. OFF PART No. DESCRIPTION 81-104-066 MAINS ON/OFF SWITCH 81-200-103 COUNTER (NON-RESETTABLE) 81-120-060 PUSHBUTTON 81-106-254 CONTROL PANEL OVERLAY 81-106-244 CONTROL ENCLOSURE...
  • Page 30 PARTS LIST & EXPLODED DIAGRAM TERMINAL/FUSE ASSEMBLY. FUSES 3 x 10A - PILOT ARC 1 x 4A - 230V SUPPLY ASSEMBLY WHEN PILOT ARC RESISTORS ARE FITTED ITEM No. OFF PART No. DESCRIPTION 81-106-043 DIN RAIL END STOP 75-101-728 DIN RAIL TERMINAL 81-106-051 DIN RAIL 81-106-041...
  • Page 31 PARTS LIST & EXPLODED DIAGRAM PILOT ARC BRACKET ASSEMBLY NOTE! RESISTORS (2) CAN BE EXCHANGED FOR CHOKES (81-109-003) IF REQUIRED (IMPROVES PILOT ARC WHEN USING GAS). ITEM No. OFF PART No. DESCRIPTION 81-106-245 PILOT ARC BRACKET 81-106-216 PILOT ARC RESISTOR 81-106-071 PILOT ARC CONTACTOR 70-102-100...
  • Page 32 PARTS LIST & EXPLODED DIAGRAM GUN SPLITTER ASSEMBLY * QUANTITY DEPENDENT SMALLER ASSEMBLY ON CONTROLLER MODEL FITTED TO 2 GUN MODEL ITEM No. OFF PART No. DESCRIPTION 70-102-047 THYRISTOR CLAMP 70-102-046 THYRISTOR 81-106-225 HEATSINK (3 & 4 GUN MODELS) Z600-08-040 WASHER 81-113-021 MOUNTING PILLAR...
  • Page 33 PARTS LIST & EXPLODED DIAGRAM ITEM No. OFF PART No. DESCRIPTION 81-106-081 81-106-242 BACK PANEL 81-104-220 FAN GRILLE PFX-CSS-B06-BUL SHIELDING GAS INLET SOCKET 81-108-019 MAINS CABLE ENTRY GLAND 81-106-297 SERIAL DATA LABEL ITEMS NOT SHOWN. ITEM No. OFF PART No. DESCRIPTION 81-106-263 WIRING HARNESS - MAIN LOOM...
  • Page 34 PCB’s - LED GUIDE (see page 9 for display PCB LED’s) V-21A...

  • Page 35: Circuit Schematics

    CIRCUIT SCHEMATICS V-21A...
  • Page 36 CIRCUIT SCHEMATICS V-21A...
  • Page 37 CIRCUIT SCHEMATICS V-21A...
  • Page 38 CIRCUIT SCHEMATICS V-21A...
  • Page 39 CIRCUIT SCHEMATICS V-21A...
  • Page 40 CIRCUIT SCHEMATICS V-21A...
  • Page 41 CIRCUIT SCHEMATICS V-21A...
  • Page 42 ACCESSORIES All the earth connection sockets on the controller are bussed on the same internal busbar. It is possible to weld with only one earth connection but where possible connect 2 earth cables to every workpiece (see page 11. Setting up and Welding) as this gives better re- sults.

  • Page 43: Eu Declaration Of Conformity

    Dewsbury West Yorkshire WF13 2BD Designation of Product : Studwelding equipment ARC4000 series. Models 1200E Multi Gun & 1600E Multi Gun Studwelding gun series DA2-A to DA20 The above mentioned equipment complies with the requirements of the following directives :...

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