V
-
21A
OPERATING GUIDE
FOR
TYPE 1200E
DRAWN ARC CONTROLLER
TAYLOR STUDWELDING SYSTEMS LIMITED
Page 1: ...V 21A OPERATING GUIDE FOR TYPE 1200E DRAWN ARC CONTROLLER TAYLOR STUDWELDING SYSTEMS LIMITED...
Page 2: ...ON TO STUDWELDING 8 GUIDE TO EXTERNAL FEATURES 11 SETTING UP AND WELDING 14 WELDING TIME AND CURRENT SETTINGS 15 VISUAL WELD INSPECTION 16 WELD TESTING 19 STUDWELDING TECHNIQUES 22 PARTS LIST EXPLODED...
Page 3: ...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 PURPOSE AND CONTENT OF THIS GUIDE This guide has bee...
Page 4: ...regarding the safety of the machine PLEASE READ THIS GUIDE CAREFULLY BEFORE INSTALLING OR OPERATING THE CONTROLLER PLEASE OBSERVE CAREFULLY ALL SAFETY PROCEDURES INSTRUCTIONS DUE TO THE POWER REQUIRE...
Page 5: ...el working in close proximity must wear suitable eye ear and body protection Fumes and gases can seriously harm your health Use the equipment only in a suitably ventilated area If ventilation is inade...
Page 6: ...site chosen for the equipment is able to support the weight of the equipment and that it will not fall or cause a danger in the course of its normal operation Do not hang connecting cables over sharp...
Page 7: ...ay from the work piece simultaneously striking an arc between the two Both the tip of the weld stud and the surface of the work piece melt as the arc is sustained for a pre determined interval At the...
Page 8: ...ANDLE NOT FOR LIFTING 2 MAINS ON OFF SWITCH 3 CONTROL PANEL SEE PAGE 9 4 SHIELDING GAS OUTLET SOCKET 5 WELDING EARTH CONNECTION SOCKET 6 FRONT CASTOR SWIVEL BRAKE TYPE 7 VENTILLATION HOLES DO NOT OBST...
Page 9: ...IECE CONTACT INDICATOR GREEN 5 PISTOL LIFT COIL ENERGISED INDICATOR GREEN 6 ADJUSTER KNOB 7 WELDING TIME SETTING PUSHBUTTON 8 GAS PURGE TIME SETTING PUSHBUTTON 9 GAS FLOWING INDICATOR GREEN 10 PISTOL...
Page 10: ...XTERNAL FEATURES 10 BACK PANEL 1 LIFTING EYEBOLT 2 RATING SERIAL PLATE 3 VENTILLATION GRILLE DO NOT OBSTRUCT 4 REAR CASTORS FIXED TYPE NO BRAKE 5 SHIELDING GAS INLET SOCKET 6 3 Ph MAINS CABLE INLET GL...
Page 11: ...ent arc blow when welding takes place Prior to fitting the clamps ensure that the contact area of the work piece is free from rust paint grease etc as this will result in a poor welding connection Plu...
Page 12: ...ck mode and will need to be released and re pressed SETTING WELD TIME 1 Press and hold the welding time setting pushbutton 7 2 Turn the adjuster knob 6 until the required time is displayed in the time...
Page 13: ...t 2 Pistol lifts stud 3 Pilot Arc strikes 4 Main Arc strikes melting both stud and workpiece 5 Arc stops Pistol plunges stud into molten pool 6 Weld complete Having welded the stud draw the pistol ver...
Page 14: ...welding time current and arc gap pistol lift as covered in the table but can also include factors such as stud and work piece material type and condition ambient temperature relative humidity quality...
Page 15: ...them EXAMPLE 1 PROBLEM Insufficient heat causing the L A W to be too long and the fillet to be underdeveloped and or incomplete REMEDY Increase the welding time see page 12 EXAMPLE 2 PROBLEM Excessiv...
Page 16: ...oportion to the degree of plate contamination Welding close to some magnetic obstruction may produce uneven fillet distribution Too much power will produce a fillet that flows too easily and is lost e...
Page 17: ...finish and lubricity of threads and bearing areas of fastened parts For standard steel screws it is 0 19 to 0 25 and 0 13 to 0 17 for plated screws Anti seize materials and lubricants can lower k to...
Page 18: ...Yield Safe UTS Yield Safe M5 x 0 8 4 9 4 0 3 2 6 3 4 1 3 3 M6 x 1 0 8 2 6 7 5 3 10 6 6 9 5 5 M8 x 1 25 20 7 16 8 13 4 26 7 17 3 13 8 M10 x 1 5 40 5 32 8 26 2 52 1 33 8 27 0 M12 x 1 75 71 0 57 5 46 0...
Page 19: ...satisfactory weld settings in the down hand position before making attempts in the overhead position Since the weld metal is transferred from stud to plate in small particles in the down hand position...
Page 20: ...s underneath the template so that there is a space between the component and template this space will allow the gases developed during welding to vent properly from the ferrule shroud For any further...
Page 21: ...results cannot be obtained our field staff will be pleased to advise you Check that no other fault is present by welding a few studs on to a test piece and inspecting the fillet formation before decid...
Page 22: ...ODED DIAGRAM 22 1 2 3 4 5 6 ITEM No OFF PART No DESCRIPTION 1 1 81 106 269 SIDE PANEL 2 1 81 112 011 HANDLE NOT FOR LIFTING 3 1 81 106 270 TOP COVER 4 2 81 106 128 EYEBOLT 5 1 81 106 268 SIDE PANEL 6...
Page 23: ...A SEE PAGE 26 FOR A BREAKDOWN OF THE BREAKDOWN OF THE BREAKDOWN OF THE FRONT PANEL ASSEMBLY BASEPLATE ASSEMBLY BACK PANEL ASSEMBLY 1 2 3 ITEM No OFF PART No DESCRIPTION 1 2 81 106 267 CASTOR MOUNTING...
Page 24: ...RAIL 6 4 81 106 041 FUSEHOLDER 7 3 75 101 728 TERMINAL 8 2 PFE P06 U1M GAS FITTING 9 1 81 108 071 GAS VALVE 10 3 70 102 100 RECTIFIER ITEM QTY PART No DESCRIPTION 11 2 81 106 216 RESISTOR 12 1 81 106...
Page 25: ...1 200 003 CONTROL PANEL OVERLAY 4 1 81 106 287 FRONT PANEL 5 1 81 200 102 DISPLAY PCB 6 1 81 200 101 GUN PCB 7 1 81 200 100 MAIN PCB 8 1 81 106 278 CONTROL BOX 9 1 81 104 030 KNOB 10 1 81 104 032 KNOB...
Page 26: ...7 1 PFX CSS B06 BUL GAS SOCKET 8 1 81 104 220 FAN FINGER GUARD 9 1 81 108 019 CABLE GLAND 10 1 81 113 032 AUXILIARY TRANSFORMER ITEM No OFF PART No DESCRIPTION 1 1 81 106 301A WIRING HARNESS MAIN LOOM...
Page 27: ...V 21A PCB s LED GUIDE see page 9 for display PCB LED s 27...
Page 28: ...V 21A CIRCUIT SCHEMATIC 28...
Page 29: ...A pair of ca bles comprises 2 off the standard cable assembly part number listed below STANDARD EARTH CABLE ASSEMBLY FOR SYSTEM 1200 99 101 090 Spare parts for the maintenance of earth cables are list...
Page 30: ...romagnetic Compatibility Directive The above mentioned products conform to the following European standards EN 60974 1 2012 ARC WELDING EQUIPMENT PART 1 WELDING POWER SOURCES EN60974 10 2014 ARC WELDI...
