Related Manuals for Taylor i16
Summary of Contents for Taylor i16
- Page 1 TAYLOR STUDWELDING SYSTEMS LIMITED OPERATING GUIDE TYPE i16 DRAWN ARC CONTROLLER V-1C...
- 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. CIRCUIT SCHEMATIC. ACCESSORIES. EC DECLARATION OF CONFORMITY.
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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
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-1C... -
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: 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 7 INTRODUCTION TO STUDWELDING The Taylor Studwelding i16 Drawn Arc controller when matched with an appropriate pistol and earth cables is intended for precision stud welding up to 16 mm diameter reduced base studs. The controller is easily transportable and has been designed to operate with a minimum amount of maintenance.
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Page 8: On/Off Switch
GUIDE TO EXTERNAL FEATURES FRONT PANEL CONTROL KNOB/PUSHBUTTON CARRYING HANDLES ON/OFF SWITCH MULTI-FUNCTION DISPLAY SHIELDING GAS INLET INDICATOR LEDS (SEE PAGE 9) WELDING PISTOL SOCKET WELDING EARTH SOCKET SHIELDING GAS OUTLET VENT - DO NOT OBSTRUCT! PISTOL CONTROL SOCKET V-1C... - Page 9 GUIDE TO EXTERNAL FEATURES CONTROL PANEL MULTI-FUNCTION DISPLAY UNIT - USED TO SELECT OPERATIONAL PARAMETERS ETC. AND REPORT BACK INFORMATION CONTACT/ERROR LED - DURING NORMAL WELDING OPERATIONS THIS LED GLOWS AMBER TO INDICATE STUD TO PLATE CONTACT WITHOUT WHICH A WELD CANNOT TAKE PLACE. IF AN ERROR OR FAULT CONDITION OCCURS, THIS LED GLOWS RED TO DRAW ATTENTION TO THE OCCURRENCE.
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Page 10: Back Panel
GUIDE TO EXTERNAL FEATURES BACK PANEL 4m CABLE WITH 3 Ph MAINS CONNECTOR 3 Ph MAINS CABLE INLET GLAND RATING/SERIAL PLATE VENTILLATION GRILLE - ! DO NOT OBSTRUCT ! V-1C... - 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 32A motor rated fuse/breaker. Plug the welding earth cables into the controller.
- Page 12 SETTING UP AND WELDING If optional shielding gas is to be used during welding. Attach the bottle supply to the controller via the front panel using a suitable self-sealing push-on socket. Connect the gas pipe from the pistol to the output socket on the front panel (optional).
- Page 13 SETTING UP AND WELDING By rotating the control knob, select either: -> Change Change Load -> Load And press the control knob to confirm selection. Selecting Change will take you through the following series of manual weld parameter setting screens: CURRENT TIME SAVE...
- Page 14 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 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 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.
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Page 18: 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 19 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 20 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 21 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 22 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.
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Page 23: Parts List & Exploded Diagram
PARTS LIST & EXPLODED DIAGRAM ITEM No. OFF PART No. DESCRIPTION 98-103-050 WARNING LABEL 98-103-066 WARNING LABEL 81-112-011 CARRYING HANDLE Z100-10-020 SCREW 71-300-008 MAINS 3Ph CABLE (PART No. per m) 81-108-073 MAINS PLUG (32A, 3P+N+E) 81-300-070 L H SIDE STICKER 81-300-104 HOUSING COVER Z620-05-000... -
Page 24: Fascia Panel
PARTS LIST & EXPLODED DIAGRAM REAR PANEL POWER PACK SEE PAGE 27 SEE PAGES 28 - 30 FASCIA PANEL SEE PAGE 26 BASEPLATE SEE PAGE 25 ITEM No. OFF PART No. DESCRIPTION 81-300-055 SPACER Z620-05-000 WASHER Z200-05-008 SCREW Z620-06-000 WASHER Z115-06-020 SCREW 81-113-024... - Page 25 PARTS LIST & EXPLODED DIAGRAM ITEM No. OFF PART No. DESCRIPTION 81-300-075 OUTPUT INDUCTOR 70-105-053 81-300-074 OUTPUT INDUCTOR 81-300-056 HOUSING BASEPLATE Z200-04-010 SCREW Z615-04-000 WASHER Z600-04-000 WASHER Z105-04-010 SCREW 81-106-262 LABEL 81-104-083 SPACER V-1C...
- Page 26 PARTS LIST & EXPLODED DIAGRAM ITEM PART No. DESCRIPTION Z200-05-008 SCREW Z620-05-000 WASHER 81-300-063 REAR VENT PANEL 81-106-262 LABEL 81-300-064 REAR PANEL 81-300-071 SERIAL/DATA LABEL 98-103-057 WARNING LABEL 98-103-055 TEST LABEL 81-300-065 SPACER 81-108-019 CABLE GLAND V-1C...
- Page 27 PARTS LIST & EXPLODED DIAGRAM 17,18 ITEM No. PART No. DESCRIPTION ITEM No. PART No. DESCRIPTION 81-106-031 WELDING SOCKET 12 Z200-04-010 SCREW 81-104-066 ON/OFF SWITCH 81-108-072 GAS OUTLET 71-200-067 GAS INLET Z200-03-010 SCREW 81-300-027 KNOB 70-102-025 CONTROL SOCKET 81-300-028 KNOB CAP 81-300-058 FASCIA PANEL 81-106-262 LABEL 81-300-060 CONTROL OVERLAY...
- Page 28 PARTS LIST & EXPLODED DIAGRAM ITEM PART No. DESCRIPTION Z650-04-000 81-300-067 INSULATOR 81-106-262 LABEL Z200-04-010 SCREW Z615-04-000 WASHER Z600-04-000 WASHER 81-300-084 BULKHEAD PANEL PFE-P06-U1M GAS FITTING 81-108-071 GAS VALVE 98-103-052 WARNING LABEL 71-300-008 3Ph LINK CABLE 81-106-257 GROMMET 81-300-082 MAINS FILTER 70-105-233 Z105-04-016 SCREW...
- Page 29 PARTS LIST & EXPLODED DIAGRAM ITEM No. PART No. DESCRIPTION Z205-04-008 SCREW ITEM No. PART No. DESCRIPTION 81-300-022 CABLE TIE MOUNT 81-300-011 RECTIFIER 98-103-052 WARNING LABEL Z120-04-018 SCREW Z115-06-012 SCREW 70-105-190 EARTH BLOCK Z615-06-000 WASHER 81-106-262 LABEL Z600-06-000 WASHER 81-300-088 PSU PCB Z115-05-016 SCREW 70-105-228 SPACER Z615-05-000 WASHER...
- Page 30 17 Z600-05-000 WASHER 81-300-073 WELD TRANSFORMER 81-300-072 WELD TRANSFORMER 81-300-052 Tx MOUNT 81-300-050 HEATSINK HALF 81-300-010 OUTPUT DIODE 81-300-076 800A JOINER Z115-05-020 SCREW 81-106-262 LABEL PART No. DESCRIPTION 81-300-095 i16 WIRING HARNESS 81-300-096 IGBT DATA CABLE - YELLOW - i16 V-1C...
- Page 31 CIRCUIT SCHEMATIC - POWER TRAIN V-1C...
- Page 32 CIRCUIT SCHEMATIC - CONTROL CIRCUIT V-1C...
- Page 33 ACCESSORIES Both the earth connection sockets on the controller are bussed on the same internal bus- bar. 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 results.
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Page 34: Declaration Of Conformity
DECLARATION OF CONFORMITY Responsible Party Name : Taylor Studwelding Systems Ltd Address : Commercial Road Dewsbury West Yorkshire WF13 2BD In accordance with the following directives : 93/68/EEC The CE Marking Directive 2014/35/EU The Low Voltage Directive 2014/30/EC The Electromagnetic Compatibility Directive...