Taylor i16 User manual

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OPERATING GUIDE
FOR
TYPE i16
DRAWN ARC CONTROLLER
TAYLOR STUDWELDING
SYSTEMS LIMITED

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INDEX
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.
17 WELD TESTING.
20 STUDWELDING TECHNIQUES.
23 PARTS LIST & EXPLODED DIAGRAMS.
31 CIRCUIT SCHEMATIC.
33 ACCESSORIES.
34 EC DECLARATION OF CONFORMITY.

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USEFUL INFORMATION
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
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 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 400V AC @ 50Hz
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 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 nocaon.

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IMPORTANT SAFETY INFORMATION !
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 the 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 !
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 37kg and is suitable for 2 person liing. It is ed with
appropriate carrying handles to allow liing by hand. The controller is suitable for use 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 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 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”
condion.

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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.
The energy required to carry out the welding operaon is derived from a fully micro-
processor controlled power inverter 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 100ms 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
FRONT PANEL
1. CARRYING HANDLES
2. MULTI-FUNCTION DISPLAY
3. INDICATOR LEDS (SEE PAGE 9)
4. WELDING EARTH SOCKET
5. VENT - DO NOT OBSTRUCT!
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2
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11
6. CONTROL KNOB/PUSHBUTTON
7. ON/OFF SWITCH
8. SHIELDING GAS INLET
9. WELDING PISTOL SOCKET
10. SHIELDING GAS OUTLET
11. PISTOL CONTROL SOCKET

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GUIDE TO EXTERNAL FEATURES
CONTROL PANEL
1. MULTI-FUNCTION DISPLAY UNIT - USED TO SELECT OPERATIONAL PARAMETERS ETC. AND
REPORT BACK INFORMATION
2. 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. FURTHER INFORMATION IS DISPLAYED ON THE MULTI-FUNCTION DISPLAY
3. TRIGGER LED - INDICATES THAT PISTOL TRIGGER HAS BEEN ACTIVATED
4. GAS LED - INDICATES THAT SHIELDING GAS FLOW IS ACTIVATED
5. GUN LIFT LED - INDICATES THAT THE GUN LIFT HAS BEEN ACTIVATED
6. WELD LED - INDICATES THAT THE WELD CURRENT HAS BEEN ACTIVATED
7. CONTROL KNOB - INCORPORATING PUSH BUTTON FUNCTION - USED FOR INTERACTION WITH
MULTI-FUNCTION DISPLAY
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GUIDE TO EXTERNAL FEATURES
BACK PANEL
1. 4m CABLE WITH 3 Ph MAINS CONNECTOR
2. 3 Ph MAINS CABLE INLET GLAND
3. RATING/SERIAL PLATE
4. VENTILLATION GRILLE - ! DO NOT OBSTRUCT !
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