Taylor 1200E User manual

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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 STUDS

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INDEX
2
PAGE No. CONTENT
3USEFUL INFORMATION.
5IMPORTANT SAFETY INFORMATION.
7INTRODUCTION TO STUDWELDING.
8GUIDE 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 DIAGRAMS.
34 PCB’s - LED GUIDE
35 CIRCUIT SCHEMATICS
42 ACCESSORIES.
43 EC DECLARATION OF CONFORMITY.

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USEFUL INFORMATION
3
MANUFACTURERS DETAILS
TAYLOR STUDWELDING SYSTEMS LIMITED
COMMERCIAL ROAD
DEWSBURY
WEST YORKSHIRE
WF13 2BD
ENGLAND
TELEPHONE :[phone]
FACSIMILE :[phone]
email :[e-mail]
WEB :www.taylor-studwelding.com
SALES DIRECT TEL :[phone]
TECHNICAL HELPLINE :[phone]
You may wish to record the details of your controller below as this informaon will help
with any technical assistance you may require:
PURPOSE AND CONTENT OF THIS GUIDE
This guide has been wrien for :
• The personnel of the end-user responsible for the installaon and maintenance of the
controller.
• The operator of the welding controller.
This guide contains informaon relang to :
• Installaon and connecon.
• Operaon.
• Technical specicaons and parameters.
• Spare parts.
CONTROLLER SERIAL No.
DATE PURCHASED.

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USEFUL INFORMATION
4
FURTHER INFORMATION
Should you require addional technical informaon, 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 informaon which is a pre-requisite for safe operaon
of the equipment. The operang 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 pass 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 them 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.
Taylor Studwelding Systems Limited reserves the right to amend the contents of this guide without nocaon.

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IMPORTANT SAFETY INFORMATION !
5
PROTECT YOURSELF AND OTHERS !
Read and understand these safety notes.
1. ELECTRICAL
No poron of the outer cover of the welding controller should be removed by anyone other
than suitably qualied 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.
Installaon must be according to the seng up procedure detailed on page 11 of this guide
and must be in line with naonal, regional and local safety codes.
2. FIRE
During welding small parcles of very hot metal are expelled. Ensure that no combusble
materials can be ignited by these.
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 protecon.
Fumes and gases can seriously harm your health. Use this equipment only in a suitably
venlated area. If venlaon is inadequate, then appropriate fume extracon equipment
must be used.
Hot metal spaer can cause re and burns. Appropriate clothing must be worn. Clothing
made from, or soiled with, combusble materials must NOT be worn.
Have a re exnguisher nearby and know how to use it.
Magnec elds from high currents can aect heart pacemakers or other electronically
controlled medical devices. It is imperave that all personnel likely to come into the vicinity
of any welding plant are warned of the possible risks before entering the area.
4. MAINTENANCE
All cables must be inspected regularly to ensure that no danger exists from worn or
damaged insulaon or from unsound electrical connecons. 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.

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IMPORTANT SAFETY INFORMATION !
6
5. TRAINING
Use of the equipment must 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. 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 operaon.
Do not hang connecng cables over sharp edges and do not install connecng cables near
heat sources or via trac routes where people may trip over them or they may be
damaged by the passage of vehicles (forklis etc).
7. INTERFERENCE
During welding operaons, intense magnec and electrical elds are unavoidably produced
which may interfere with other sensive Electronic equipment.
All Taylor Studwelding equipment is designed, manufactured and tested to conform the
current appropriate European standards and direcves regarding electromagnec
emissions and immunity and as such is safe to use in any normal industrial 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 known to be toxic, carcinogenic or harmful to health in their “as
supplied” condion.

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INTRODUCTION TO STUDWELDING
7
The Taylor Studwelding 1200E/1600E Drawn Arc Mul Gun controller when matched with
up to 4 appropriate pistols and earth cables is intended for precision stud welding up to
16/20 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 operaon is derived from a fully micro-
processor controlled transformer-recer inside the controller.
Taylor Studwelding Systems Ltd pistols are modern, ergonomically designed and oer
maximum comfort in handling with minimum operator fague.
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 posion, the pistol lis 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 compleon 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 tradional drawn arc welds have a weld duraon 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 formaon 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 duraon 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 pracce in short
cycle welding to employ a suitable shielding gas to reduce the amount of porosity in the
completed weld and improve weld quality.

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GUIDE TO EXTERNAL FEATURES
8
1
2
3
4
5
6
7
8
9
10
FRONT PANEL
1. GUIDING HANDLE - ! NOT FOR LIFTING !
2. MAINS ON/OFF SWITCH
3. PISTOL 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 LIFTING)
7. CONTROL PANEL (SEE PAGE 9)
8. SHIELDING GAS OUTLET SOCKET
9. VENTILLATION HOLES - ! DO NOT OBSTRUCT !
10. FRONT CASTOR (SWIVEL & BRAKE TYPE)

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GUIDE TO EXTERNAL FEATURES
9
CONTROL PANEL
1. WELD COUNTER (NON-RESETTABLE)
2. PUSHBUTTON (WELD CURRENT SETTING/CURRENT READBACK)
3. PUSHBUTTON (WELD TIME SETTING/ERROR CODE READBACK)
4. DISPLAY WINDOW (WELD CURRENT SET/CURRENT READBACK)
5. DISPLAY WINDOW (WELD TIME 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 CONTACT)
10. INDICATOR (PISTOL TRIGGER ACTIVATED (1 TO 4, MODEL DEPENDENT))
11. INDICATOR (PISTOL LIFT COIL ACTIVATED (1 TO 4, MODEL DEPENDENT))
12. INDICATOR (WELD CONTROLLER OVER TEMPERATURE)
13. INDICATOR (WELD CONTROLLER MAINS SUPPLY FAULT)
123456
78910 11 12 13

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GUIDE TO EXTERNAL FEATURES
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 (CABLE NOT SHOWN).
1
2
3
4
5
6