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21A

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

’

LED GUIDE

CIRCUIT SCHEMATICS

ACCESSORIES.

EC DECLARATION OF CONFORMITY.

Содержание 1200E

Страница 1: ...1A OPERATING GUIDE FOR TYPE 1200E 1600E MULTI GUN DRAWN ARC CONTROLLERS 2 3 4 GUN MODELS TAYLOR STUDWELDING SYSTEMS LIMITED A TAYLORMADE DRAWN ARC STUDWELDING SYSTEM TO WELD UP TO 16mm REDUCED BASE ST...

Страница 2: ...TO STUDWELDING 8 GUIDE TO EXTERNAL FEATURES 11 SETTING UP AND WELDING 15 WELDING TIME AND CURRENT SETTINGS 16 VISUAL WELD INSPECTION 18 WELD TESTING 21 STUDWELDING TECHNIQUES 24 PARTS LIST EXPLODED D...

Страница 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...

Страница 4: ...of the name and address of the new owner in case we need to contact them regarding the safety of the machine PLEASE READ THIS GUIDE CAREFULLY BEFORE INSTALLING OR OPERATING THE CONTROLLER PLEASE OBSER...

Страница 5: ...nnel working in close proximity must wear suitable eye ear and body protection Fumes and gases can seriously harm your health Use this equipment only in a suitably ventilated area If ventilation is in...

Страница 6: ...connecting cables near heat sources or via traffic routes where people may trip over them or they may be damaged by the passage of vehicles forklifts etc 7 INTERFERENCE During welding operations inte...

Страница 7: ...s the stud away 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 int...

Страница 8: ...WELDING CONNECTION SOCKET MODEL DEPENDENT UP TO 4 4 PISTOL CONTROL CONNECTION SOCKET MODEL DEPENDENT UP TO 4 5 WELDING EARTH CONNECTION SOCKET MODEL DEPENDENT UP TO 4 6 ADVISORY STICKER NOT FOR LIFTI...

Страница 9: ...ME SET SHIELDING GAS PURGE TIME SET ERROR CODE READBACK 6 ADJUSTER KNOB 7 PUSHBUTTON SHIELDING GAS PURGE SETTING PARAMETER READBACK 8 INDICATOR SHIELDING GAS PURGE ACTIVATED 9 INDICATOR STUD TO PLATE...

Страница 10: ...ATURES 10 BACK PANEL 1 LIFTING EYEBOLTS 2 VENTILLATION GRILLES DO NOT OBSTRUCT 3 RATING SERIAL PLATE 4 REAR CASTORS FIXED TYPE NO BRAKE 5 SHIELDING GAS INLET SOCKET 6 3 PHASE MAINS CABLE INLET GLAND C...

Страница 11: ...rea of the work piece is free from rust paint grease etc as this will result in a poor welding connection Plug the pistol control cable into the controller Note that the cable end plug and panel mount...

Страница 12: ...the pistol you want to set up and activate the trigger The display window 4 will briefly display an identifier for the pistol From this point until a trigger is activated on another connected pistol a...

Страница 13: ...setting pushbutton 7 2 Turn the adjuster knob 6 until the required time is displayed in the time display window 5 The time is adjustable between 0 and 5000ms in 100ms increments 3 Release the pushbutt...

Страница 14: ...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...

Страница 15: ...he table but can also include factors such as stud and work piece material type and condition ambient temperature relative humidity quality of supply etc All of these factors can act on the weld to ch...

Страница 16: ...t the stud has a complete well formed and even fillet and is also perpendicular to the work piece The following examples will help you to recognise the most common types of poor weld explain the possi...

Страница 17: ...PROBLEM Poor alignment i e stud is not perpendicular to the workpiece REMEDY Hold the pistol perpendicular to the work piece see page 14 NOTE If the misalignment is only slight and in all other aspec...

Страница 18: ...ination 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 either up in the threads of the stud or...

Страница 19: ...ed 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 0 05 For some stainless steel threads and parts not coated o...

Страница 20: ...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 91 3 59 2 47 4 M16 x 2 0 181 0 146 5 117 2 232 8 150 9 120 7 20 Mild Steel M...

Страница 21: ...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...

Страница 22: ...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...

Страница 23: ...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...

Страница 24: ...ART No DESCRIPTION 1 1 81 120 032 HANDLE NOT FOR LIFTING 2 1 81 106 260 ADVISORY STICKER 3 2 81 106 128 EYEBOLT 4 1 81 106 253 TOP COVER 5 1 81 106 252 SIDE PANEL 6 2 81 106 265 STICKER 1200 MODEL or...

Страница 25: ...SEE PAGE 29 FOR A MORE DETAILED BREAKDOWN OF THE CONTROL HOUSING ASSEMBLY SEE PAGE 33 FOR A MORE DETAILED BREAKDOWN OF THE BACK PANEL ASSEMBLY SEE PAGE 26 27 FOR A MORE DETAILED BREAKDOWN OF THE OUTP...

Страница 26: ...ESE PANELS QUANTITIES FOR EACH MODEL ARE AS SHOWN IN VIEWS ABOVE ITEM No OFF PART No DESCRIPTION 1 81 106 249 SINGLE BLANKING SUB PANEL 2 81 106 250 DOUBLE PISTOL SUB PANEL PISTOLS 1 2 3 81 106 248 SI...

Страница 27: ...3 4 3 PFX CSS B06 BUL SHIELDING GAS OUTLET SOCKET 4 70 102 025 CONTROL SOCKET 5 81 106 031 WELD SOCKET 6 81 106 182 PANEL DECAL SET PISTOL EARTH 7 81 106 250 DUAL PISTOL SUB PANEL PARTS LIST EXPLODED...

Страница 28: ...1 81 106 236 1200A WELDING TRANSFORMER or 1 81 106 200 1600A WELDING TRANSFORMER 4 1 81 106 289 TRANSFORMER MOUNT PLATE 1600 MODEL ONLY 5 6 81 106 218 SNUBBER 6 1 81 106 195 SHUNT 7 2 81 106 241 SUPP...

Страница 29: ...STOL PCB 8 81 200 101 PISTOL CONTROL PCB 1 PER PISTOL 9 1 81 106 296 AUXILIARY TRANSFORMER 10 1 81 106 295 AUXILIARY TRANSFORMER 11 1 81 200 100 MAIN PCB 12 1 81 113 032 AUXILIARY TRANSFORMER 13 1 81...

Страница 30: ...FUSES 3 x 20A PILOT ARC 1 x 4A 230V SUPPLY ASSEMBLY WHEN PILOT ARC CHOKES ARE FITTED ITEM No OFF PART No DESCRIPTION 1 2 81 106 043 DIN RAIL END STOP 2 7 75 101 728 DIN RAIL TERMINAL 3 1 81 106 051 DI...

Страница 31: ...9 10 11 12 ITEM No OFF PART No DESCRIPTION 1 1 81 106 245 PILOT ARC BRACKET 2 2 81 106 216 PILOT ARC RESISTOR 3 1 81 106 071 PILOT ARC CONTACTOR 4 3 70 102 100 RECTIFIER 5 4 81 106 272 TERMINAL 6 1 81...

Страница 32: ...EPENDENT SMALLER ASSEMBLY ON CONTROLLER MODEL FITTED TO 2 GUN MODEL ITEM No OFF PART No DESCRIPTION 1 70 102 047 THYRISTOR CLAMP 2 70 102 046 THYRISTOR 3 1 81 106 225 HEATSINK 3 4 GUN MODELS 4 4 Z600...

Страница 33: ...AINS CABLE ENTRY GLAND 6 1 81 106 297 SERIAL DATA LABEL ITEM No OFF PART No DESCRIPTION 1 1 81 106 263 WIRING HARNESS MAIN LOOM 2 1 81 106 264 WIRING HARNESS SECONDARY LOOM 3 4 71 300 008 MAINS FLEXIB...

Страница 34: ...V 21A PCB s LED GUIDE see page 9 for display PCB LED s 34...

Страница 35: ...V 21A CIRCUIT SCHEMATICS 35...

Страница 36: ...V 21A CIRCUIT SCHEMATICS 36...

Страница 37: ...V 21A CIRCUIT SCHEMATICS 37...

Страница 38: ...V 21A CIRCUIT SCHEMATICS 38...

Страница 39: ...V 21A CIRCUIT SCHEMATICS 39...

Страница 40: ...V 21A CIRCUIT SCHEMATICS 40...

Страница 41: ...V 21A CIRCUIT SCHEMATICS 41...

Страница 42: ...page 11 Setting up and Welding as this gives better re sults An earth cable must be connected to the controller in this user guide A pair of ca bles comprises 2 off the standard cable assembly part nu...

Страница 43: ...EU The Electromagnetic 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 2...

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