Taylor ARC4000 Series Manual de usuario
V-21A
OPERATING GUIDE
FOR
TYPE 1200E
DRAWN ARC CONTROLLER
TAYLOR STUDWELDING
SYSTEMS LIMITED
V-21A
INDEX
2
PAGE No. CONTENT
3USEFUL INFORMATION.
5IMPORTANT SAFETY INFORMATION.
7INTRODUCTION TO STUDWELDING.
8GUIDE 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 DIAGRAMS.
27 PCB’s - LED GUIDE.
28 CIRCUIT SCHEMATIC.
29 ACCESSORIES.
30 DECLARATION OF CONFORMITY
V-21A
USEFUL INFORMATION
3
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
WEB :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 informaon will help
with any technical assistance you may require:
PURPOSE AND CONTENT OF THIS GUIDE
This guide has been wrien for :
• The personnel of the end-user responsible for the installaon and maintenance of the
controller.
• The operator of the welding controller.
This guide contains informaon relang to :
• Installaon and connecon.
• Operaon.
• Technical specicaons and parameters.
• Spare parts.
CONTROLLER SERIAL No.
DATE PURCHASED.
V-21A
USEFUL INFORMATION
4
FURTHER INFORMATION
Should you require addional technical informaon, please contact us directly (details
on previous page) or our local agent / distributor (details of agents etc. can be obtained
from us).
This guide contains important informaon which is a pre-requisite for safe Operaon
of the equipment. The operang personnel must be able to consult this guide when
necessary. In the interests of safety, make this guide available to your personnel in good
me.
If the equipment is sold / passed on, please hand over this manual to the new owner
and if possible please inform us of the name and address of the new owner, in case we
need to contact him 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 REQUIREMENTS AND ELECTROMAGNETIC EMISSIONS
PRODUCED DURING NORMAL USE, THIS MACHINE MUST ONLY BE OPERATED IN
AN INDUSTRIAL ENVIRONMENT.
THIS MACHINE OPERATES FROM A MAINS SUPPLY OF 380/415V AC @ 50/60 Hz
NEVER REMOVE ANY PORTION OF THE UNIT HOUSING WITHOUT FIRST
ISOLATING THE CONTROLLER FROM THE MAINS ELECTRICAL SUPPLY.
NEVER OBSTRUCT THE UNDERSIDE, FRONT OR REAR PANELS AS THIS MAY
CAUSE THE UNIT TO OVERHEAT DURING OPERATION.
DO NOT USE THIS WELDING POWER SOURCE FOR PIPE THAWING.
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 nocaon.
V-21A
IMPORTANT SAFETY INFORMATION !
5
PROTECT YOURSELF AND OTHERS !
Read and understand these safety notes.
ELECTRICAL
No poron of the outer cover of the welding controller should be removed by anyone other
than suitably qualied personnel and never whilst mains power is connected.
ALWAYS DISCONNECT THE MAINS LEAD BEFORE ATTEMPTING ANY
MAINTENANCE.
BEWARE - RISK OF ELECTRIC SHOCK !
Do not use any uids to clean electrical components as these may penetrate into the
electrical system.
Installaon must be according to the seng up procedure detailed on page 11 of this guide
and must be in line with naonal, regional and local safety codes.
FIRE
During welding small parcles of very hot metal are expelled. Ensure that no combusble
materials can be ignited by these.
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 protecon.
Fumes and gases can seriously harm your health. Use the equipment only in a suitably
venlated area. If venlaon is inadequate, then appropriate fume extracon equipment
must be used.
Hot metal spaer can cause re and burns. Appropriate clothing must be worn. Clothing
made from, or soiled with, combusble materials must NOT be worn.
Have a re exnguisher nearby and know how to use it.
Magnec elds from high currents can aect heart pacemakers or other electronically
controlled medical devices. It is imperave that all personnel likely to come into the vicinity
of any welding plant are warned of the possible risks before entering the area.
MAINTENANCE
All cables must be inspected regularly to ensure that no danger exists from worn or
damaged insulaon or from unsound electrical connecons. Special note should be made
of the cables close to the pistol, where maximum wear occurs. As well as producing
inconsistent welds, worn cables can overheat or spark, giving rise to the risk of re.
V-21A
IMPORTANT SAFETY INFORMATION !
6
5. TRAINING
Use of the equipment must be limited to authorised personnel only who must be suitably
trained and must have read and understood this manual. This manual must be made
available to all operators at all mes. Further copies of this manual may be purchased from
the manufacturer. Measures must be taken to prevent the use of this equipment by
unauthorised personnel.
6. LIMITATIONS OF USE
The mass of the welding controller is 150kg and not suitable for man liing. It is ed with
suitable castors to enable man powered movement on at, level, smooth surfaces only. The
welding controller is also ed with appropriate liing points to allow liing by crane/
forkli truck. The controller is not suitable for use in rain or snow or in an environment with
increased risk of electric shock.
6. INSTALLATION
Ensure that the 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 operaon.
Do not hang connecng cables over sharp edges and do not install connecng cables near
heat sources or via trac routes where people may trip over them or they may be
damaged by the passage of vehicles (forklis etc).
7. INTERFERENCE
During welding operaons, intense magnec and electrical elds are unavoidably produced
which may interfere with other sensive Electronic equipment.
All Taylor Studwelding equipment is designed, manufactured and tested to conform the
current appropriate European standards and direcves regarding electromagnec
emissions and immunity and as such is safe to use in any normal environment.
8. DISPOSAL
The equipment either wholly or any of its component parts may be disposed of as part of
general industrial waste or passed to a scrap merchant. None of the components used in
the manufacture are toxic, carcinogenic or harmful to health in their “as supplied”
condion.
V-21A
INTRODUCTION TO STUDWELDING
7
The Taylor Studwelding 1200E 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.
The energy required to carry out the welding operaon is derived from a fully micro-
processor controlled transformer-recer inside the controller.
Taylor Studwelding Systems Ltd pistols are modern, ergonomically designed and oer
maximum comfort in handling with minimum operator fague.
THE PROCESS
The process of drawn arc studwelding is long established and well proven. The basic steps
are as follows :
• A measured amount of weld stud protrusion is set at the welding pistol.
• Once in posion, the pistol lis the stud away from the work-piece, simultaneously
striking an arc between the two.
• Both the p of the weld stud and the surface of the work-piece melt as the arc is
sustained for a pre-determined interval.
• At the compleon of the pre-determined interval, the pistol returns the weld stud to
the molten pool on the work-piece, thus forming a weld.
The most common and tradional drawn arc welds have a weld duraon greater than
100ms and employ the use of a single use ceramic arc shield, commonly referred to as a
ferrule. This ferrule helps to protect the arc during the weld and assists in formaon of the
nal llet. Post welding the ferrule is removed and disposed of.
It is possible to stud weld without a ferrule. This method is more commonly employed with
welds having a duraon of less than 100 ms and this type of weld is referred to as short
cycle stud welding. Although no ferrule is employed, it is recommended pracce in short
cycle welding to employ a suitable shielding gas to reduce the amount of porosity in the
completed weld and improve weld quality.
V-21A
GUIDE TO EXTERNAL FEATURES
8
FRONT PANEL
1. GUIDING HANDLE ! 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 OBSTRUCT !
8. PISTOL CONTROL CONNECTION SOCKET
1
2
3
4
5
6
7
8
9
V-21A
GUIDE TO EXTERNAL FEATURES
9
CONTROL PANEL
1. CURRENT SETTING PUSHBUTTON
2. WELDING TIME/GAS PURGE TIME DISPLAY WINDOW
3. WELDING CURRENT DISPLAY WINDOW
4. STUD TO WORK PIECE 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 TRIGGER ACTUATED INDICATOR - GREEN
11. CONTROLLER OVER TEMPERATURE INDICATOR - RED (STOPS WELDING)
12. SUPPLY FAULT INDICATOR - RED (INDICATES LOSS OF PHASE)
123456
78910 11 12
V-21A
GUIDE TO EXTERNAL 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 GLAND
1
2
3
4
5
6
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