Taylor SIK2-H Operating Manual

Capacitor discharge automatic stud welding head

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TAYLOR

STUDWELDING

SYSTEMS LIMITED.

OPERATING GUIDE

FOR

SIK2-H CAPACITOR DISCHARGE

AUTOMATIC STUD WELDING HEAD

V-3H

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Summary of Contents for Taylor SIK2-H

Page 1 TAYLOR STUDWELDING SYSTEMS LIMITED. OPERATING GUIDE SIK2-H CAPACITOR DISCHARGE AUTOMATIC STUD WELDING HEAD V-3H...
Page 2: Table Of Contents
INDEX PAGE CONTENT GENERAL INFORMATION INTRODUCTION GENERAL ARRANGEMENT FEED SEQUENCE SAFETY EXPLOSION DRAWINGS & PARTS LISTS MAKING ADJUSTMENTS PLUNGE SPEED CHANGING STUD DIAMETER CHANGING COLLETS COLLET TYPES STUD FEED HOSE CHANGING FLICKERS FLICKER TYPES HEAD UP SENSOR WELD QUALITY TROUBLE SHOOTING EC DECLARATION OF CONFORMITY V-3H...
Page 3: General Information
GENERAL 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 e-mail info@taylor-studwelding.com TECHNICAL TEL +44 (0)1924 487703 SALES TEL +44 (0)1924 487701 PURPOSE AND CONTENT OF THIS MANUAL This manual has been wri@en for : The operator of the welding machine.
Page 4: Further Information
Please read this manual carefully before installa on of the machine. Please especially observe the safety instruc ons. Taylor Studwelding Systems Limited reserves the right to amend the contents of this manual without noCﬁcaCon. V-3H...
Page 5: Introduction
INTRODUCTION INTRODUCTION The complete range of Taylor Studwelding Systems Capacitor Discharge units are compact, portable Stud Welding equipments. The units are speciﬁcal- ly designed to enable a small diameter range of ferrous and non-ferrous weld studs to be welded to light gauge, self-ﬁnish or pre-coated materials, in most cases with li@le or no reverse marking.
Page 6: Technical Data
SIK 2 WELDING HEAD TECHNICAL DATA Part number : 99-100-144 Weight 1.5kg without welding cable Drive PneumaCc cylinder Guide shaJ hardened & ground Weld stroke 50mm V-3H...
Page 7 WELDING SEQUENCE In the start posiCon, the nose insert holder with a stud in place is posiConed approx. 50mm above the workpiece. At the start of the welding process, the nose insert holder moves towards the workpiece. Welding begins when the stud touches the workpiece.
Page 8: Safety
SAFETY PROTECT YOURSELF AND OTHERS ! Read and understand these safety noCces. 1. ELECTRICAL No porCon of the outer cover of the welding controller should be re- moved by anyone other than suitably qualiﬁed personnel and never whilst mains power is connected. ALWAYS disconnect the mains plug from the socket. RISK TO LIFE !!! BE AWARE ! This equipment contains a sealed power supply module...
Page 9: Maintenance
SAFETY 3. PERSONNEL SAFETY Arc rays can burn your eyes and skin and noise can damage your hearing. Operators and personnel working in close proximity must wear suitable eye, ear and body protecCon. Fumes and gases can seriously harm your health. Use the equipment only in a suitably venClated area.
Page 10: Installation
Electronic equip- ment. All Taylor Studwelding equipment is designed, manufactured and tested to conform the current appropriate European standards and direcCves regard- ing electromagneCc emissions and immunity and as such is safe to use in any normal environment.
Page 11 WELD HEAD EXPLOSION & PARTS LIST V-3H...
Page 12 WELD HEAD EXPLOSION & PARTS LIST Note: There are 2 types of head up sensor. New heads have an inducCve proximity switch. Older heads have a mechanical switch. To use the older type of switch re- place items 12, 13 and 15 with 71-105-061 V-3H...
Page 13 WELD HEAD EXPLOSION & PARTS LIST V-3H...
Page 14 WELD HEAD EXPLOSION & PARTS LIST SEE PAGE 33 FOR COLLET TYPES V-3H...
Page 15 WELD HEAD EXPLOSION & PARTS LIST ITEM No PART No DESCRIPTION 71-105-056 WELD BRAID 2³ 71-103-081 FEED HOSE CLAMP 71-105-054 TOP NUT 71-105-028 SHAFT LOCKWASHER 71-105-047 BUMP STOP 71-105-050 ROD END 71-105-046 DRIVE PLATE 71-105-051 BUMP STOP 71-105-049 SHAFT WASHER 71-105-048 ALIGNMENT BLOCK 71-105-043...
Page 16 WELD HEAD EXPLOSION & PARTS LIST ITEM PART No DESCRIPTION PRC-B06-B06-F00 PRECISION SPEED CONTROL 71-105-060 PNEUMATIC BRACKET PFE-P06-U1M DIA 6, 1/8 BSP ELBOW PVM-F32-M3F QUICK EXHAUST VALVE PFS-P06-U1F DIA 6, 1/8 BSP FEMALE UNION PFX-SSS-P04-U2F DIA 4 SELF SEAL BULKHEAD UNION PFS-P06-U2M-EXT DIA 6, 1/4 BSP STRAIGHT UNION PFS-P04-BUL...
Page 17 FLICKER HOUSING EXPLOSION & PARTS LIST MK1 ASSEMBLY (FITTED AS STANDARD BEFORE NOVEMBER 2012) SEE PAGE 37 FOR FLICKER TYPES A COMPLETE ASSEMBLY IS AVAILABLE UNDER PART NUMBER 71-105-069 ITEM No PART No DESCRIPTION 71-105-062 HOUSING 71-105-063 71-105-068 SPRING 71-105-065 COVER Z800-03-024 71-105-064...
Page 18 FLICKER HOUSING EXPLOSION & PARTS LIST MK2 ASSEMBLY (FITTED AS STANDARD FROM NOVEMBER 2012) SEE PAGE 37 FOR FLICKER TYPES ITEM No PART No DESCRIPTION Z800-03-024 PIVOT PIN Z400-04-008 SOCKET SET SCREW 71-105-199 MK2 FLICKER HOUSING Z100-04-008 SOCKET HEAD SCREW Z615-04-000 SPRING WASHER 71-105-063...
Page 19 SIK100 - LONG STROKE VERSION The SIK100 has an extended travel of 100mm compared to the standard SIK2 which has a travel of 50mm. This is useful when welding into the bo@om of a box, etc. A complete assembly is available under part number 99-100-159 The parts list for the SIK100 is the same as the SIK2, apart from the following items: ITEM No...
Page 20 SPRAY HEAD EXPLOSION & PARTS LIST (OPTIONAL) A COMPLETE ASSEMBLY IS AVAILABLE UNDER PART NUMBER 71-105-093 ITEM No PART No DESCRIPTION 71-200-019 1/8 BSP ELBOW 71-105-092 SPRAY HEAD BODY 71-200-239 M5 ELBOW 75-100-045 GASKET 75-100-046 FLIUD CAP 75-100-047 AIR CAP 75-100-053 RETAINER RING V-3H...
Page 21 STUD SENSOR EXPLOSION & PARTS LIST (OPTIONAL) A COMPLETE ASSEMBLY IS AVAILABLE UNDER PART NUMBER 71-105-100 ITEM No PART No DESCRIPTION 71-105-089 MOUNTING PLATE - A Z100-05-008 M5 x 8 LONG SKT HD SCREW 71-105-090 MOUNTING PLATE - B 75-101-786 STUD SENSOR Z200-03-012 M3 x 12 LONG POZIDRIVE SCREW V-3H...
Page 22 STUD GATE (OPTIONAL) The stud gate is used to prevent damage to the stud’s pip during feeding. Instead of the stud being fed directly into the weld head it is ﬁrst fed into the gate and then from here into the head. Without the stud gate the speed at which the stud is blown over into the head has to be restricted, otherwise the pip is damaged when the new stud lands on the one just welded.
Page 23 STUD GATE Screw the housing base on- to the connecCon tube unCl the feed pipe is fully home Lock the housing base in place using the feed hose clamp locknut Fit the remaining components with the cylinder to the front V-3H...
Page 24 STUD GATE Connect the cylinder to the head solenoid using T ﬁMngs Adjust the stud blow over speed—see the Bowl feed & escapement manual On CNC machines ﬁrst logon then go to the parameters screen and make the following adjustments: Change the feed type from Standard to With stud gate...
Page 25 STUD GATE EXPLOSION V-3H...
Page 26 STUD GATE PARTS LIST ITEM No PART No DESCRIPTION Z200-03-020 M3 x 20 POZIDRIVE PAN HD SCREW 71-103-081 FEED HOSE CLAMP 71-105-222 ADAPTOR SLEEVE—DIA 3 x 5 PIN 71-105-223 ADAPTOR SLEEVE—M3 71-105-224 ADAPTOR SLEEVE—M4 71-105-225 ADAPTOR SLEEVE—M5 71-105-226 ADAPTOR SLEEVE—M6 Z400-03-006 M3 x 6 HEX SKT GRUB SCREW 71-105-211...
Page 27: Making Adjustments
MAKING ADJUSTMENTS ADJUSTING FOR DIFFERENT STUD LENGTHS The weld head must be in the up posiCon. Load a stud into the collet. Loosen the ﬂicker housing clamp screws. Move the ﬂicker housing to its top posiCon. Press the stud fully up into the collet, so that the stud ﬂange is in contact with the nose in- serts.
Page 28 MAKING ADJUSTMENTS ADJUSTING HEAD HEIGHT (cont.) Fasten the workpiece into the jig. Feed a stud into the collet. Check the distance ‘a’ as shown on page 19 Turn oﬀ the air pressure, or pull tube B1 out of the pneumaCc connecCon. This connecCon has a non-return valve.
Page 29: Plunge Speed
MAKING ADJUSTMENTS ADJUSTING HEAD HEIGHT (cont.) For very short studs (6 - 8mm), adjust the welding head so that between the nose inserts and the workpiece is a gap of 2mm. Note: It is very important that without a stud in the collet that the collet does not touch the workpiece.
Page 30: Changing Stud Diameter
CHANGING COLLETS CHANGING STUD DIAMETER To change the stud diameter the following components have to be changed: Collet holder (see page 33) Flicker if needed (see page 37) Feed tube if needed (see page 35) COLLET The standard collet is made up of three parts: Holder Nose inserts Spring...
Page 31 CHANGING COLLETS REMOVING THE COLLET Switch oﬀ the air supply, or remove tube B1. Push the guide shaJ down. Loosen the clamping nut with an open span- ner. Lightly tap the collet holder with the spanner unCl the holder comes free. FITTING THE COLLET Note that the wide slot in the collet holder is oriented towards the ﬂicker.
Page 32 CHANGING COLLETS FITTING THE COLLET (cont.) The collet is held into the guide shaJ with a tapered olive, this makes sure that there is a good electrical and mechanical contact between the collet and guide shaJ. Push the collet into the guide shaJ unCl it reaches the end stop. Ensure that the slot in the collet holder, engages with the alignment pin in the guide shaJ.
Page 33: Collet Types
COLLET TYPES COLLET PART No’s Collet holder - Note: This type of collet has generally been replaced by the close centre one piece type. Use this type of collet in conjuncCon with long nose inserts if the stud is not being welded verCcally and the stud is 25mm long.
Page 34 COLLET TYPES COLLET PART No’s The collet spring and nose insert screws are available under part number 40-14111 Close centre one piece collet - Note: this is the standard type of collet ﬁ@ed to all new weld heads and auto systems. Use a nose insert holder in conjuncCon with long nose inserts instead if the stud is not being welded verCcally and the stud is 25mm long.
Page 35: Stud Feed Hose
STUD FEED HOSE STUD FEED HOSE The stud feed hose transports the stud into the welding head. The hose is made from a non-abrading polyamide. The tube diameter depends on the stud size: Stud Size Tube OD (mm) Tube ID (mm) Part No (per m) M3 Flangeless 79-103-302...
Page 36: Changing Flickers
CHANGING FLICKERS CHANGING THE FLICKER In addiCon to the standard ﬂicker, special ﬂicker for diﬀerent applicaCons are available. The table on page 35 shows the various types and their uses. REPLACEMENT The easiest way to replace the ﬂicker is to remove the ﬂicker carrier.
Page 37: Flicker Types
FLICKER TYPES V-3H...
Page 38: Head Up Sensor
HEAD UP SENSOR The weld head has a sensor to detect when the head is in the up posiCon. There are 2 diﬀerent types of sensor. New heads have an inducCve proximity switch, older heads have a mechanical switch. New Type Connector An LED turns on when the head is up.
Page 39: Weld Quality
WELD QUALITY VISUAL ASSESMENT OF WELD QUALITY A cold stud weld is noCceable by undercuMng of the ﬂange and lack of / minimal formaCon of spa@er. A cold weld is usually caused by too li@le energy and / or too fast a plunge speed. A hot stud weld is noCceable by excessive spa@er for- maCon and parCal melCng of the ﬂange.
Page 40: Mechanical Tests
WELD QUALITY Visual examinaCon of weld quality can, even with limited experience, pro- vide a useful quality assessment. In such a check the presence of a small even witness of weld material around the base of the stud ﬂange aJer welding should be ensured.
Page 41: Trouble Shooting
TROUBLE SHOOTING Fault / Error Cause Remedy Sudden decline in weld Worn welding Check the contacts of the quality contacts collet & earth clamps. Replace worn out parts Welding energy too high Too much spa@er around or too low the weld area: energy too high -decrease the weld voltage...
Page 42 TROUBLE SHOOTING Fault / Error Cause Remedy Studs show material Arc blow eﬀect. Apply earthing contacts ejected to one side only Earthing contacts not ap- symmetrically to the plied evenly weld posiCon Burn marks on stud Collet contact worn Replace the contact inserts No stud in the collet Stud blockage in the stud...
Page 43: Ec Declaration Of Conformity
EC DECLARATION OF CONFORMITY TAYLOR STUDWELDING SYSTEMS LIMITED COMMERCIAL ROAD DEWSBURY WEST YORKSHIRE TEL : +44 (0)1924 452123 ENGLAND FAX : +44 (0)1924 430059 WF13 2BD FAX : +44 (0)1924 430059 STATEMENT This is to certify that the machinery listed below is designed and manufactured in conformance with all applicable health and safety regulations.