Taylor SPi-10 Operating Manual
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Taylor SPi-10 Operating Manual

Taylor SPi-10 Operating Manual

Single phase drawn arc controller
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TAYLOR STUDWELDING
SYSTEMS LIMITED
OPERATING GUIDE
FOR
TYPE SPi-10
SINGLE PHASE
DRAWN ARC
CONTROLLER
1
V-21C

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Summary of Contents for Taylor SPi-10

  • Page 1 TAYLOR STUDWELDING SYSTEMS LIMITED OPERATING GUIDE TYPE SPi-10 SINGLE PHASE DRAWN ARC CONTROLLER V-21C...
  • Page 2 V-21C...
  • Page 3 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. CIRCUIT SCHEMATIC. TROUBLESHOOTING - WARNINGS & ERRORS ACCESSORIES.

  • Page 4: 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 5: Further Information

    DO NOT USE THIS WELDING POWER SOURCE FOR PIPE THAWING OR IN CONDITIONS OF RAIN OR SNOWFALL. THIS EQUIPMENT HAS BEEN EMC TESTED AND APPROVED IN ACCORDANCE WITH BS EN 60974-10 (CATEGORY 2). Taylor Studwelding Systems Limited reserves the right to amend the contents of this guide without notification. V-21C...

  • Page 6: 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 7: Limitations Of Use

    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 environment.
  • Page 8 INTRODUCTION TO STUDWELDING The Taylor Studwelding SPi-10 Drawn Arc controller when matched with an appropriate pistol and earth cables is intended for precision stud welding up to 10 mm diameter reduced base studs. The controller is easily transportable and has been designed to operate with a minimum amount of maintenance.
  • Page 9 GUIDE TO EXTERNAL FEATURES FRONT PANEL HANDLE CONTROL KNOB/PUSHBUTTON MULTI-FUNCTION DISPLAY INDICATOR LEDS (SEE PAGE 9) ON/OFF SWITCH MAINS FUSEHOLDER WELDING EARTH (+) SOCKET WELDING PISTOL (-) SOCKET SHIELDING GAS INLET PISTOL CONTROL SOCKET WHEELS V-21C...
  • Page 10 GUIDE TO EXTERNAL FEATURES CONTROL PANEL MULTI-FUNCTION DISPLAY UNIT - USED TO SELECT OPERATIONAL PARAMETERS ETC. AND REPORT BACK INFORMATION CONTACT LED - INDICATES STUD TO PLATE CONTACT WITHOUT WHICH A WELD CANNOT TAKE PLACE. NOTE! THIS IS A BI-COLOUR LED AS IT IS ALSO USED TO INDICATE FAULT/ERROR CONDITIONS ALONGSIDE ADDITIONAL INFORMATION DISPLAYED ON THE MULTI-FUNCTION DISPLAY.

  • Page 11: Back Panel

    GUIDE TO EXTERNAL FEATURES BACK PANEL SHIELDING GAS INLET MAINS CABLE INLET GLAND RATING/SERIAL PLATE V-21C...
  • Page 12 SETTING UP AND WELDING Set up the control unit in a suitable location at the place of work, ensuring that the controller mains switch is in the OFF position. Plug the controller into a single phase AC supply. NOTE! The controller is able to operate on 110V AC &240V AC supplies, when fitted with an appropriate mains plug or via an adaptor.
  • Page 13 SETTING UP AND WELDING If an optional shielding gas is being used. Plug the pistol gas connector into the quick release socket on the front panel. Connect the bottle supply to the quick release bayonet on the back panel of the controller. NOTE! Using shielding gas will not only improve the quality of welding but also lower the power requirement of the controller during operation.
  • Page 14 For example. If a very poor/low current supply is all that is available, the rate could be set to LOW or MIN to prevent over-loading the supply/breaker. Information on how to change the charging rate is not contained in this operating guide but can be supplied upon request by emailing a support request to sales@taylor-studwelding.com or contacting us directly by phone. V-21C...
  • Page 15 SETTING UP AND WELDING Upon completion of the start-up sequence. The controller is ready to weld. The controller parameters at this point will be the ones that were set at the last switch off (as displayed on Current Parameter Set screen, see previous page). If these are the parameters you wish to use.
  • Page 16 SETTING UP AND WELDING Selecting Change will take you into the manual weld parameter setting screens: The first of which is the “Current” screen. Which is used to set the welding output current. The value is shown in Amps (A) and is adjustable between 10A and 800A in 5A steps.
  • Page 17 SETTING UP AND WELDING TURN the knob to set the required welding time. Once the desired number is reached the choices are as previously outlined. Either go to the “Save to” screen using PRESS & HOLD or move on to the next parameter screen using PRESS &...
  • Page 18 SETTING UP AND WELDING From page 14. Selecting Load will take you to the parameter load screen. If you have previously saved a parameter set to one of the 25 memory locations in the controller memory. You can recall those parameters using this screen.
  • Page 19 SETTING UP & WELDING - SUPPLEMENTAL SCREENS The display has 5 different display screens when in normal operating mode. These can be accessed by simply turning the adjuster knob in either direction. The main display screens which have been previously described are: Current Parameter Set Charge Status Screen There is also a Power - Counter screen:...
  • Page 20 SETTING UP AND WELDING Set up the welding pistol in-line with the operating guide supplied with the pistol. Ensuring that there is sufficient stud protrusion and that the stud is centred in the ferrule/foot assembly. Place the pistol perpendicular to the work piece with the stud touching down at the desired location to be welded.
  • Page 21 This page is intended as a guide to setting your machine. The SPi-10 Single Phase Inverter Drawn Arc Stud Welder uses inverter technology to charge a bank of high energy storage capacitors from a single phase mains supply. Because the energy used to perform welding operations is stored, it is therefore finite and users need to be aware of this.
  • Page 22 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 23 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 +0/-1 mm.

  • Page 24: 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 25 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 26 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 27 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 28 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 29: Parts List & Exploded Diagram

    PARTS LIST & EXPLODED DIAGRAM ITEM No. OFF PART No. DESCRIPTION 81-300-156 SIDE STICKER 81-300-152 HOUSING COVER 81-300-157 SIDE STICKER Z620-05-000 WASHER Z200-05-008 SCREW V-21C...
  • Page 30 PARTS LIST & EXPLODED DIAGRAM ITEM PART No. DESCRIPTION ITEM PART No. DESCRIPTION 81-108-067 ON/OFF SWITCH 81-300-155 LOWER PANEL OVERLAY 81-104-030 KNOB 81-106-031 WELDING SOCKET 81-104-032 KNOB CAP PFX-CSS-B06-BUL GAS OUTLET 81-300-154 UPPER PANEL OVERLAY 70-102-025 CONTROL SOCKET 81-300-151 FRONT PANEL Z200-03-010 SCREW 81-300-025...
  • Page 31 PARTS LIST & EXPLODED DIAGRAM 17, 18 NOT SHOWN # CORDSET W/PLUG (NOT SHOWN) 70-102-015 UK 230V PLUG 70-102-222 EURO SCHUKO 220V PLUG 70-105-028 UK 115V YELLOW PLUG ITEM PART No. DESCRIPTION ITEM PART No. DESCRIPTION 81-300-132 FILTER 81-300-088 81-300-136 GROMMET 81-300-092 PCB MOUNT...
  • Page 32 PARTS LIST & EXPLODED DIAGRAM ITEM No. PART No. DESCRIPTION ITEM No. PART No. DESCRIPTION Z200-04-008 SCREW 81-300-097 Z610-04-000 WASHER 81-300-092 PCB MOUNT 81-300-098 70-105-228 PILLAR 81-113-146 GROMMET 81-300-147 BULKHEAD Z105-05-016 SCREW Z200-05-008 SCREW Z615-05-000 WASHER Z620-05-000 WASHER 81-300-091 81-300-081 FERRITE Z205-04-008 SCREW Z855-04-035 PILLAR...
  • Page 33 PARTS LIST & EXPLODED DIAGRAM ITEM No. PART No. DESCRIPTION Z100-08-016 SCREW 81-300-161 SERIAL PLATE ITEM No. PART No. DESCRIPTION 81-300-164 HANDLE CLAMP 81-300-148 BASEPLATE 81-300-163 HANDLE TUBE Z505-06-000 NUT 81-300-138 HAND GRIP Z615-06-000 WASHER Z115-06-035 SCREW Z600-06-020 WASHER Z600-06-000 WASHER 81-300-166 LINK BAR Z200-05-012 SCREW...
  • Page 34 PARTS LIST & EXPLODED DIAGRAM V-21C...
  • Page 35 PARTS LIST & EXPLODED DIAGRAM ITEM QTY. PART No. DESCRIPTION 81-300-158 TRANSFORMER 81-300-133 CHARGE RESISTOR Z200-04-012 SCREW Z615-04-000 WASHER Z600-04-000 WASHER Z200-05-012 SCREW Z620-05-000 WASHER 81-300-019 INDUCTOR 81-300-150 Tx BRACKET 81-300-081 FERRITE Z120-05-012 SCREW Z115-08-012 SCREW Z620-08-000 WASHER 81-300-022 CABLE TIE BASE 81-300-146 SINK PLATE Z115-06-020...
  • Page 36 PARTS LIST & EXPLODED DIAGRAM V-21C...
  • Page 37 PARTS LIST & EXPLODED DIAGRAM ITEM QTY. PART No. DESCRIPTION Z860-08-035 PILLAR Z615-03-000 WASHER Z515-05-000 Z605-05-999 WASHER Z865-05-010 PILLAR 81-300-143 LINK BUSBAR Z115-08-012 SCREW 70-105-258 INSULATOR 81-300-144 CAPACITOR CARRIER 70-105-259 INSULATOR Z650-12-000 81-300-145 CARRIER MOUNT Z200-03-006 SCREW 81-300-168 RESISTOR Z615-05-000 WASHER Z406-05-022 SCREW...

  • Page 38: Circuit Schematic

    CIRCUIT SCHEMATIC V-21C...
  • Page 39 CIRCUIT SCHEMATIC V-21C...
  • Page 40 TROUBLESHOOTING - WARNINGS & ERRORS The internal software of the controller, amongst other things, is constantly monitoring various aspects of the system. Occasionally, should conditions warrant it, the multi-function display may report a Warning condition. This will usually be accompanied by an audible tone from the controller.

  • Page 41: Important Note

    TROUBLESHOOTING - WARNINGS & ERRORS CODE DESCRIPTION ACTION F502 POWER LIMIT REACHED Avoid high duty cycle welding at high current outputs or with long welding extension cables. F503-F509 DISPLAY CONTROL FAULT CONTACT SUPPLIER F510 PISTOL NOT DETECTED CHECK PISTOL IS FITTED/FUNCTIONAL F511-F512 GAS VALVE FAULT CONTACT SUPPLIER F513...
  • Page 42 ACCESSORIES An earth cable must be connected to the controller in this user guide. STANDARD EARTH CABLE ASSEMBLY FOR SYSTEM SPi-10 99-101-095 Spare parts for the maintenance of earth cables are listed below: WELD PLUG 81-101-051 CABLE/m 71-300-005 EARTH CLAMP...

  • Page 43: Eu Declaration Of Conformity

    Commercial Road Dewsbury West Yorkshire WF13 2BD Designation of Product : Inverter Studwelding Equipment. Model SPi-10 Studwelding gun series DA2-A to DA20 The above mentioned equipment complies with the requirements of the following directives : 93/68/EEC The CE Marking Directive...

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