Taylor CD-i User manual

V‐4J
TAYLOR
STUDWELDING
SYSTEMSLIMITED
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OPERATINGGUIDE
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FOR
TYPECD‐i
CAPACITORDISCHARGE
STUDWELDINGEQUIPMENT
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ATAYLORMADECAPACITORDISCHARGESTUDWELDINGSYSTEM

V‐4J
INDEX
2
PAGENo. CONTENT
3 USEFULINFORMATION.
5 IMPORTANTSAFETYINFORMATION.
7 INTRODUCTIONTOSTUDWELDING.
8 GUIDETOEXTERNALFEATURES.
10 SETTINGUPANDWELDING.
12 WELDSETTINGS.
14 WELDTESTING.
15 PARTSLIST&EXPLODEDDIAGRAMS.
22 CIRCUITSCHEMATIC‐WIRING.
23 DECLARATIONOFCONFORMITY.

V‐4J
USEFULINFORMATION
3
MANUFACTURERSDETAILS
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 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informaonwillhelp
withanytechnicalassistanceyoumayrequire:
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PURPOSEANDCONTENTOFTHISGUIDE
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Thisguidehasbeenwrienfor:
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 Thepersonneloftheend‐userresponsiblefortheinstallaonandmaintenanceofthe
controller.
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 Theoperatoroftheweldingcontroller.
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Thisguidecontainsinformaonrelangto:
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 Installaonandconnecon.
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 Operaon.
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 Technicalspecificaonsandparameters.
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 Spareparts.
CONTROLLERSERIALNo. 
DATEPURCHASED. 

V‐4J
USEFULINFORMATION
4
FURTHERINFORMATION
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 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.
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
PLEASEOBSERVECAREFULLYALLSAFETYPROCEDURES/INSTRUCTIONS.
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THISEQUIPMENTHASBEENEMCTESTEDANDAPPROVEDINACCORDANCE
WITHBSEN60974‐10(CATEGORY2).
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THISMACHINEOPERATESFROMAMAINSSUPPLYOF100‐250VAC@50Hz
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NEVERREMOVEANYPORTIONOFTHEUNITHOUSINGWITHOUTFIRST
ISOLATINGTHECONTROLLERFROMTHEMAINSELECTRICALSUPPLY.
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NEVEROBSTRUCTTHEUNDERSIDE,FRONTORREARPANELSASTHISMAY
CAUSETHEUNITTOOVERHEATDURINGOPERATION.
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DONOTUSETHISWELDINGPOWERSOURCEFORPIPETHAWING.
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TaylorStudweldingSystemsLimitedreservestherighttoamendthecontentsofthisguidewithoutnoficaon.

V‐4J
IMPORTANTSAFETYINFORMATION!
5
PROTECTYOURSELFANDOTHERS!

Readandunderstandthesesafetynotes.
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1.ELECTRICAL
Noporon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plugfromthesocket.
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 BEAWARE! Capacitorsstoreelectricalenergy.Checkforresidual 
    chargebeforecarryingoutanyinternalmaintenance.

 DONOT!  useanyfluids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10ofthis
manual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.
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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 fire and burns. Appropriate clothing must be worn. Clothing
madefrom,orsoiledwith,combusblematerialsmustNOTbeworn.
Haveafireexnguishernearbyandknowhowtouseit.
Magnec fields from high currents can affect 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.
Tominimisetherisksofexposuretoelectromagnecradiaon,operatorsshouldnotdrape
theweldingcablesovertheirshouldersorwrapthemaroundthemselvesinanywaywhilst
usingtheequipment.Itisalsorecommendedthatoperatorsroutetheweldingearthreturn
cablesawayfromthemselvesanddonotstandbetweenthetwoearthreturncablesduring
welding.


V‐4J
IMPORTANTSAFETYINFORMATION!
6
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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fire.
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5.LIMITATIONSOFUSE
Themassoftheweldingcontrollerisbetween11and13.3kgdependantonthemodel
purchasedandassuchissuitabletobemanhandled.Thecontrollerisnotsuitableforusein
rainorsnoworinanenvironmentwithincreasedriskofelectricshock.
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6.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.
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7.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trafficrouteswherepeoplemaytripoverthemortheymaybe
damagedbythepassageofvehicles(forklisetc.)
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8.INTERFERENCE
Duringweldingoperaons,intensemagnecandelectricalfieldsareunavoidablyproduced
andthese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.
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9.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.

V‐4J
INTRODUCTIONTOSTUDWELDING
7
INTRODUCTION

 ThecompleterangeofTaylorStudweldingSystemsCapacitorDischargeunitsare
compact,portableStudWeldingequipment's.Theunitsarespecificallydesignedtoenable
asmalldiameterrangeofferrousandnon‐ferrousweldstudstobeweldedtolightgauge,
self‐finishorpre‐coatedmaterials,inmostcaseswithlileornoreversemarking.
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 Theequipmentconsistsofacontrolunit,aweldingpistolandthenecessary
interconnecngcablesandaccessories.
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
THEPROCESS

 CapacitorDischargestudweldingisaformofweldinginwhichtheenergyrequired
fortheweldingprocessisderivedfromabankofchargedcapacitors.Thisstoredenergyis
dischargedacrossthegapbetweenthetwosurfacestobeweldedastheyarepropelled
towardseachother.Thearcproducedheatsthetwosurfaces,melngathinfilmofmetal
oneachsurfaceandthepropellingforceclosesthegapbetweenthetwofaces,thus
formingaweld.
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 Incontactweldingthestudtobeweldedisforcedbyspringpressureontotheplate.
Atthispointthearcgapbetweenthetwocomponentsismaintainedbyasmallpiponthe
weldingfaceofthestud.Oniniaonofthehighcurrentpulsefromthecapacitors,thispip
vaporisesandanarcisdrawnbetweentheworkpieceandthestud.Theheatfromthisarc
meltsthebaseofthestudandtheareaoftheworkpiecedirectlybeneaththestud,whilst
thespringpressurefromthepistolacceleratesthestudtowardstheworkpiece.Within3
to4millisecondsthestudhitstheworkpieceandthearcisexnguished.Thekinec
energycontainedinthemovingstudandtheremainingspringpressure,forgethemolten
partstogethertoformaweld.

V‐4J
GUIDETOEXTERNALFEATURES
8
FRONTPANEL

1. CARRYINGHANDLE
2. WELDINGVOLTAGEDISPLAY
3. WELDINGVOLTAGECONTROLKNOB
4. VENTILLATIONHOLES !DONOTOBSTRUCT!
5. WELDINGEARTHPANELCONNECTOR
6. GREENLED‐INDICATESREADYTOWELD
7. AMBERLED‐INDICATESUNITISCHARGING
8. REDLED‐INDICATESUNITISINRESETMODE.WAIT10SECONDSANDRE‐STARTTHE
CONTROLLERWITHTHEON/OFFSWITCH.IFTHERESETCONDITIONPERSISTSAFAULT
HASOCCURED
9. WELDINGPISTOLCONTROLCONNECTOR
10. WELDINGPISTOLPANELCONNECTOR
1



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2
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3
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4
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
5
6
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7
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8
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9
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
10

V‐4J
GUIDETOEXTERNALFEATURES
9
BACKPANEL
1.RATING/SERIALPLATE      4.MAINFUSE
2.ON/OFFSWITCH       5.MAINSINLET‐IECSOCKETOR
3.VENTILLATIONFAN/GRILLE‐!DONOTOBSTRUCT! FIXEDCABLE(SEEINSET)
          OPTIONSAVAILABLE
IMPORTANTNOTES!
DuetothepowerrequirementsandElectromagnecemissionsproducedduringnormaluse,this
machinemustonlybeoperatedinanindustrialenvironment.

TheunithasinvertertechnologyandisdesignedtooperatefromanysinglephaseACvoltagebetween
100and250VACat50Hz.

Neverobstructthefrontandrearpanelvenlaonholesortheundersideoftheunitasthismaycause
theunittooverheatduringoperaon.

Neverremoveanyporonoftheunithousingwithoutfirstisolangtheunitfromthemainselectrical
supply.
1


2


3


4


5

V‐4J
SETTINGUPANDWELDING
10
Setupthecontrolunitattheplaceofwork,
ensuringthatthemainsswitchisintheOFF
posion.Ensurethatthisisdoneinlinewiththe
notesandsafetyrecommendaonsonpages5and
6ofthismanual.

Plugthecontrollerintothe
correctmainsACsupply.The
controllerisratedforanysingle
phaseACvoltagebetween100
and250VACat50Hz.Ensure
thecorrectplugisfiedfor
yoursupplyinlinewithlocal/
naonalcodes.
Connecttheweldingearthcabletothecontrollerpanel
mountedplug.
Notethatthecableendplughasapegwhichmateswitha
keyslotinthepanelmountedsocket.

IMPORTANT!
Securetheconnectorwitha
clockwiseturnunlitlocks.
Failuretodothiswillresultin
damagetotheconnector
duringwelding.
Aachtheweldingearthclampstotheworkpieceat
approximately180°toeachother.Thiswillhelptoprevent
"Arcblow"whenweldingtakesplace.Priortofingthe
clamps,ensurethatthecontactareaoftheworkpieceis
freefromrust,paint,greaseetc.Asthiswillresultinapoor
weldingconneconandpoorresults.Wherepossible,route
theearthcablesawayfromtheoperatortopreventtheoperatorbeingposionedbetween
therunofthecableswhilstoperangtheequipment.

Connecttheweldingpistolcabletothecontrollerpanel
mountedsocket.
Notethatthecableendplughasapegwhichmateswith
akeyslotinthepanelmountedsocket.

IMPORTANT!
Securetheconnectorwith
aclockwiseturnunlit
locks.Failuretodothis
willresultindamageto
theconnectorduring

V‐4J
SETTINGUPANDWELDING
11
Connecttheweldingpistolcontrolcabletothe
panelmountedsocketonthecontroller.

Notethatthecableendplugandpanelmounng
socketarekeyedtopreventincorrectfing.Push
theplugfirmlyhomeandtwistthelockingring
clockwisetosecurethepluginposion.








Preparethepistolforuseinaccordancewiththeguidancegiveninthedocument
“OPERATINGGUIDEFORCDSTUDWELDINGPISTOLSTYPEC2&LG2”whichaccompanies
thetypeC2pistolsuppliedwithyourcontroller.

Theguidecontainsinformaonon:

 PistolSetup
 SpareParts
 Accessories
 Safety

V‐4J
WELDSETTINGS
12
Thispageandthefollowingareintendedasaguidetosengyourmachine.

Thesengsoutlinedinthetableareonlyintendedasastarngpoint.Itispossiblethatthe
sengswillgivesasfactoryresultswithoutadjustment,butinrealitythequalityofthe
weldingresultsisgovernedbymanyvariablefactors.Theseinclude,mostobviously,the
weldingpowerandpistolspringpressureascoveredinthetable,butcanalsoinclude
factorssuchasstudandwork‐piecematerialtypeandcondion,ambienttemperature,
relavehumidity,qualityofsupplyetc.Allofthesefactorscanactontheweldtochange
theoutcome.Itisrecommendedthatinallinstances,youneedtocarryoutsamplewelds
inyouractualcondionsandenvironment.Thiswillenableyoutoalterthesengs,where
necessary,toachieveweldsthataremostacceptabletoyou.

Thesengchartswereestablishedwiththeperformanceofrepeveweldtestsusing
studsmanufacturedtotheBSENISO13918standard,inthefollowingmaterials:

   MildSteel,GradeSt37‐3
   StainlessSteel,Grade1.4303
   AluminiumAlloy,GradeAlMg3

andsheetmaterialsofthefollowingtypes:

   1.6mmThick,MildSteel,GradeCR4
   1.6mmThick,StainlessSteel,TypeS304
   1.6mmThick,AluminiumAlloy,GradeHE30,HalfHard

N.R.=NOTRECOMMENDED

V‐4J
WELDSETTINGS
13
i8 i8 i9 i9 i10 i10
STUDØ STUDM VOLTAGE SPRING VOLTAGE SPRING VOLTAGE SPRING
M2.5/M3 MS 75 2½ 45 2½ 35 2½
SS 75 2½ 45 2½ 35 2½
AL 80 2½ 50 2½ 35 2½
M4 MS 85 2½ 60 2½ 40 2½
SS 85 2½ 60 2½ 40 2½
AL 90 3½ 65 3½ 45 3½
M5 MS 105 2½ 75 2½ 65 2½
SS 110 2½ 85 2½ 65 2½
AL 110 3½ 80 3½ 70 3½
M6 MS 125 2½ 90 2½ 80 2½
SS 135 2½ 110 2½ 80 2½
AL 180 4 120 4 120 4
M8 MS 180 3½ 130 3½ 130 3½
SS 190 3½ 160 3½ 130 3½
AL NR 4 150 4 160 4
M10 MS NR 3½ 185 3½ 155 3½
SS NR 3½ NR 3½ 170 3½
ETAG MS 100 2½ 75 2½ 65 2½

V‐4J
WELDTESTING
14
Visualexaminaonofweldqualitycan,evenwithlimitedexperience,provideauseful
qualityassessment.Insuchacheckthepresenceofasmallevenwitnessofweldmaterial
aroundthebaseofthestudflangeaerweldingshouldbeensured.Poorweldsare
indicatedbyexcessmetalononesideoftheweldedflangeand/orthepresenceofan
undercutornon‐fusedareabetweenthestudflangeandtheparentsheetorplate.
Incorrectsengs,adversemagneceffectsetc.suchasthoseatedgeweldingposionsor
withunbalancedearthsandstudsweldedtotheworkpieceatanangle,thecontrollerand
pistolshouldbeexaminedwithaviewtocorrecngsuchdefects.


MECHANICALTESTS:

1.BENDING.

Themosteasilyappliedmethodoftesngthequalityofweldedfastenersconsideredhere,
involvestheuseofabendingbar.Thisbendingbar(availablefromyoursupplier,seethe
accessoriesseconofthismanual)fiedwiththecorrectsizeofnozzleforthestudtobe
testedisusedtobendoverthestudinaccordancewithBSENISO14555:2006
specificaon.

2.TORSION.

Atorsiontestprovidesusefulinformaonforthreadedfasteners.Thisinvolvesghteninga
nutonthestudagainstaspacer,suitablyrelievedtocaterfortheflangeandweldspaer.
Forquantaveassessmentsasuitablycalibratedtorquewrenchmaybeused,butatits
simplest,aspannerwillsuffice.


Intheaboveteststheperformanceoftheweldedjointshouldbeconsideredinrelaonto
thethicknessofthematerialtowhichthestudiswelded.Onthickermaterials,afull
strengthweldisdenotedbydeformaonorfailureofthestudshank.Onlightergauge
material,severe"dimpling"or"dishing"atthereversetotheweldsidenormallyindicates
sufficientstrength,whilstinmostcases,thetearingofaslugofmaterialfromtheparent
sheetwilloccur.

V‐4J
PARTSLIST&EXPLODEDDIAGRAMS
15
1234



5



6
ITEM No.OFF PARTNo. DESCRIPTION
1 10 Z200‐05‐008 SCREW
2 1 70‐105‐014 HANDLE
3 2 Z105‐08‐025 SCREW
4 1 70‐105‐237 LOGOSTICKER
5 1 70‐105‐230 COVER
6 1 SEEINSET MODELIDENTSTICKER
MODEL LH RH
i8 70‐105‐238 70‐105‐239
i9 70‐105‐240 70‐105‐241
i10 70‐105‐242 70‐105‐243

V‐4J
PARTSLIST&EXPLODEDDIAGRAMS
16
SEEPAGES22TO24FORA
BREAKDOWNOFTHECAPACITORBANK


























SEEPAGE20FORABREAKDOWN    SEEPAGE21FORABREAKDOWN
OFTHEBASEPLATE      OFTHEBACKPANEL

V‐4J
PARTSLIST&EXPLODEDDIAGRAMS
17
ITEM No.OFF PARTNo. DESCRIPTION
1 1 81‐104‐030 KNOB
2 1 81‐104‐032 KNOBCAP
3 2 Z200‐03‐010 SCREW
4 1 70‐102‐025 PANELCONTROLSOCKET
5 1 70‐105‐231 CONTROLPANELOVERLAY
6 1 70‐105‐227 BASEPLATE
7 4 Z200‐03‐006 SCREW
8 4 Z610‐03‐000 WASHER
9 1 70‐105‐220 DISPLAYPCB
10 2 81‐106‐031 PANELWELDSOCKET
11 1 70‐105‐232 SOCKETPANELOVERLAY
12 4 70‐102‐002 FOOT
13 4 Z100‐04‐016 SCREW
4 5 6 7
3 8
1,2 9
10 11 12 13

V‐4J
PARTSLIST&EXPLODEDDIAGRAMS
18
ITEM No.OFF PARTNo. DESCRIPTION
1 1 70‐105‐294 FAN
2 1 70‐105‐229 BACKPANEL
3 1 70‐105‐244 SERIAL/RATINGPLATE
4 1 70‐102‐018 FANGUARD
5 1 70‐105‐270 ON/OFFSWITCH
6 4 Z650‐03‐000 RIVET
7 4 Z200‐05‐012 SCREW
8 1 70‐102‐085 FUSEHOLDER
9 1 70‐105‐236 FUSE
10 1 70‐105‐249 IECINLET
11 2 Z200‐05‐008 SCREW
12 1 70‐105‐248 ADAPTERPLATE(OPTIONALINSTEADOFIECINLET)
13 1 70‐102‐075 CABLEGLAND(OPTIONALINSTEADOFIECINLET)
12345
6


7


8


9



10


NOTE:ITEM10ORITEMS11‐13AREFITTED    11  12  13




















MAINSCORDSETSAVAILABLE(NOTSHOWNABOVE)
70‐105‐016 UKBS1363PLUGTOIEC
70‐102‐017 EUROSCHUKOCEE7/7PLUGTOIEC
70‐105‐028 UKYELLOWBS4343PLUGTOIEC
70‐102‐044 USANEMAGROUNDEDPLUGTOIEC
70‐102‐015 UKBS1363PLUGTOSTRIPPEDENDS
70‐102‐222 EUROSCHUKOCEE7/7PLUGTOSTRIPPEDENDS

V‐4J
PARTSLIST&EXPLODEDDIAGRAMS
19
ITEM No.OFF PARTNo. DESCRIPTION
1 1 70‐105‐221 MAINPCB
2 5 Z600‐03‐000 WASHER
3 5 Z200‐03‐006 SCREW
4 5 70‐105‐228 MOUNTINGPILLAR
5 1 70‐105‐226 WARNINGSTICKER
6 1 70‐105‐247 CAPACITOR
8 1 70‐105‐245 WIRINGHARNESS(NOTSHOWN)
7 1 70‐105‐219 RESISTOR
1  2  3

















4  5  6

7

V‐4J
PARTSLIST&EXPLODEDDIAGRAMS
20
ITEM No.OFF PARTNo. DESCRIPTION
1 1 Z200‐05‐008 SCREW
2 1 NA DIODELEAD
3 2 Z605‐10‐000 WASHER
4 1 70‐105‐225 SOCKETLINKBAR
5 2 Z510‐10‐000 LOCKNUT
6 4 Z105‐05‐045 SCREW
7 5 Z615‐05‐000 SPRINGWASHER
8 5 Z600‐05‐000 WASHER
9 1 70‐105‐224 POSITIVEBUSBAR
10 4 70‐105‐139 CAPACITORSCREW
11 4 Z605‐05‐999 WASHER
12 4 Z615‐05‐000 SPRINGWASHER
13 4 Z515‐05‐000 NUT
14 # 70‐102‐131 DIODE‐#NOTE.2OFFINi8,3OFFINi9&i10MODELS
15 1 70‐102‐047 THYRISTORCLAMP
16 1 70‐102‐046 THYRISTOR
17 1 70‐106‐044 CLAMPPLATE
13

12

11

10

    6 7 8 9

1 2 3 4 5







14151617