Taylor CD-i Operating Manual

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.

COMMERCIAL ROAD DEWSBURY WEST YORKSHIRE WF13 2BD ENGLAND TELEPHONE : +44 (0)1924 452123 FACSIMILE : +44 (0)1924 430059 email : [email protected] 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 information will help with any technical assistance you may require: PURPOSE AND CONTENT OF THIS GUIDE This guide has been written for : • The personnel of the end-user responsible for the installation and maintenance of the controller. • The operator of the welding controller. This guide contains information relating to : • Installation and connection. • Operation. • Technical specifications and parameters. • Spare parts. CONTROLLER SERIAL No. DATE PURCHASED.

on previous page) or our local agent / distributor (details of agents etc. can be obtained from us). This guide contains important information which is a pre-requisite for safe Operation of the equipment. The operating personnel must be able to consult this guide when necessary. In the interests of safety, make this guide available to your personnel in good time. 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. THIS EQUIPMENT HAS BEEN EMC TESTED AND APPROVED IN ACCORDANCE WITH BS EN 60974-10 (CATEGORY 2). THIS MACHINE OPERATES FROM A MAINS SUPPLY OF 100-250V 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. Taylor Studwelding Systems Limited reserves the right to amend the contents of this guide without notification.

5 PROTECT YOURSELF AND OTHERS ! Read and understand these safety notes. 1. ELECTRICAL No portion 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. 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 Installation must be according to the setting up procedure detailed on page 10 of this manual and must be in line with national, regional and local safety codes. 2. FIRE During welding small particles of very hot metal are expelled. Ensure that no combustible 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 protection. Fumes and gases can seriously harm your health. Use the equipment only in a suitably ventilated area. If ventilation is inadequate, then appropriate fume extraction equipment must be used. Hot metal spatter can cause fire and burns. Appropriate clothing must be worn. Clothing made from, or soiled with, combustible materials must NOT be worn. Have a fire extinguisher nearby and know how to use it. Magnetic fields from high currents can affect heart pacemakers or other electronically controlled medical devices. It is imperative 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 electromagnetic radiation, 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.

6 4. MAINTENANCE All cables must be inspected regularly to ensure that no danger exists from worn or damaged insulation or from unsound electrical connections. 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. 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. 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 times. 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. 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 operation. Do not hang connecting cables over sharp edges and do not install connecting cables near heat sources or via traffic routes where people may trip over them or they may be damaged by the passage of vehicles (forklifts etc.) 8. INTERFERENCE During welding operations, intense magnetic and electrical fields are unavoidably produced and these may interfere with other sensitive Electronic equipment. All Taylor Studwelding equipment is designed, manufactured and tested to conform the current appropriate European standards and directives regarding electromagnetic emissions and immunity and as such is safe to use in any normal environment. 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” condition.

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 little or no reverse marking. The equipment consists of a control unit, a welding pistol and the necessary interconnecting cables and accessories. 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, melting a thin film of metal on each surface and the propelling force closes the gap between the two faces, thus forming a weld. 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 initiation 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 extinguished. The kinetic energy contained in the moving stud and the remaining spring pressure, forge the molten parts together to form a weld.

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 2 3 4 5 6 7 8 9 10

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 Electromagnetic 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 ventilation holes or the underside of the unit as this may cause the unit to overheat during operation. Never remove any portion of the unit housing without first isolating the unit from the mains electrical supply. 1 2 3 4 5

10 Set up the control unit at the place of work, ensuring that the mains switch is in the OFF position. Ensure that this is done in line with the notes and safety recommendations 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 fitted for your supply in line with local/ national 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 until it locks. Failure to do this will result in damage to the connector during welding. Attach 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 fitting 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 connection and poor results. Where possible, route the earth cables away from the operator to prevent the operator being positioned between the run of the cables whilst operating 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 until it locks. Failure to do this will result in damage to the connector during

11 Connect the welding pistol control cable to the panel mounted socket on the controller. Note that the cable end plug and panel mounting socket are keyed to prevent incorrect fitting. Push the plug firmly home and twist the locking ring clockwise to secure the plug in position. 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 information on : • Pistol Setup • Spare Parts • Accessories • Safety

The settings outlined in the table are only intended as a starting point. It is possible that the settings will give satisfactory 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 condition, ambient temperature, relative 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 conditions and environment. This will enable you to alter the settings, where necessary, to achieve welds that are most acceptable to you. The setting charts were established with the performance of repetitive 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-21A 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

quality assessment. In such a check the presence of a small even witness of weld material around the base of the stud flange after 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 settings, adverse magnetic effects etc. such as those at edge welding positions 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 correcting such defects. MECHANICAL TESTS : 1. BENDING. The most easily applied method of testing the quality of welded fasteners considered here, involves the use of a bending bar. This bending bar (available from your supplier, see the accessories section of this manual) fitted 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 specification. 2. TORSION. A torsion test provides useful information for threaded fasteners. This involves tightening a nut on the stud against a spacer, suitably relieved to cater for the flange and weld spatter. For quantitative 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 relation to the thickness of the material to which the stud is welded. On thicker materials, a full strength weld is denoted by deformation 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.

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

16 SEE PAGES 19 TO 21 FOR A BREAKDOWN OF THE CAPACITOR BANK SEE PAGE 17 FOR A BREAKDOWN SEE PAGE 18 FOR A BREAKDOWN OF THE BASEPLATE OF THE BACK PANEL

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

18 ITEM No. OFF PART No. DESCRIPTION 1 1 70-105-294 FAN 2 1 70-105-229 BACK PANEL 3 1 70-105-142 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

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 70-105-219 RESISTOR 7 1 70-105-245 WIRING HARNESS (NOT SHOWN) 1 2 3 4 5 6

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

21 ITEM No. OFF PART No. DESCRIPTION 1 6 Z205-04-016 SCREW 2 4 Z515-05-000 NUT 3 4 Z615-05-000 SPRING WASHER 4 4 Z605-05-999 WASHER 5 4 70-105-139 CAPACITOR SCREW 6 # 70-105-258 INSULATOR 7 # 70-105-259 INSULATOR 1 8 2 9 3 10 4 11 5 12 6 13 7 ITEM No. OFF PART No. DESCRIPTION 8 2 70-105-234 INSULATED FIXING BLOCK 9 2 70-105-235 MOUNTING PILLAR 10 1 70-105-223 NEGATIVE BUSBAR 11 # 70-105-040 CAPACITOR 12 1 70-105-222 MOUNTING BRACKET 13 # Z510-12-000 LOCKNUT # QTY VARIES BY MODEL. i8 = 2, i9 = 3, i10 = 4

Responsible Party Name : Taylor Studwelding Systems Ltd Address : Commercial Road Dewsbury West Yorkshire WF13 2BD UK Designation of Product : Studwelding equipment CDi series types CDi8, CDi9, CDi10 Studwelding gun series C1, C2 The above mentioned equipment complies with the requirements of the following directives : 93/68/EEC The CE Marking Directive 2014/35/EU The Low Voltage Directive 2014/30/EU The Electromagnetic Compatibility Directive The above mentioned products conform to the following European standards : EN 60974-1:2012 ARC WELDING EQUIPMENT - PART 1 : WELDING POWER SOURCES EN60974-10:2014 ARC WELDING EQUIPMENT - PART 10 : ELECTROMAGNETIC COMPATIBILITY (EMC) REQUIREMENTS I hereby declare that the above mentioned equipment has been designed to comply with the relevant sections of the above referenced standards. The equipment complies with all applicable essential requirements of the above mentioned directives. Signed. David Taylor Managing Director Authorised European Representative : J D PEARMAN GLENN MILLERWEG 36 1311 RT ALMERE NETHERLANDS