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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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
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4
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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