Taylor CD-MULTIGUN Manual de usuario
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TAYLOR STUDWELDING
SYSTEMS LIMITED.
OPERATING GUIDE
FOR
CD-MULTIGUN
COMPACT CAPACITOR DISCHARGE
STUDWELDING EQUIPMENT
A TAYLORMADE CAPACITOR DISCHARGE PRODUCT
VISIT OUR WEBSITE
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INDEX
PAGE CONTENT
3GENERAL INFORMATION
5INTRODUCTION
6EQUIPMENT SCHEDULE
7EXTERIOR FEATURES
9SAFETY
12 SETTING UP AND WELDING
17 WELD SETTINGS
20 LOCATION METHODS
21 WELD ASSESSMENT / TESTING
22 CONTROLLER EXPLOSION AND PARTS LIST
28 CIRCUIT SCHEMATIC
29 EC DECLARATION OF CONFORMITY
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GENERAL INFORMATION
MANUFACTURERS DETAILS
TAYLOR STUDWELDING SYSTEMS LIMITED
COMMERCIAL ROAD
DEWSBURY
WEST YORKSHIRE
WF13 2BD ADD US TO YOUR CONTACTS
ENGLAND
TELEPHONE :+44 (0)1924 452123
FACSIMILE :+44 (0)1924 430059
e-mail :sales@taylor-studwelding.com
TECHNICAL TEL :+44 (0)1924 487703
SALES TEL :+44 (0)1924 487701
WEB :www.taylor-studwelding.com
FIND US ON GOOGLE MAPS →
PURPOSE AND CONTENT OF THIS MANUAL
This manual has been wrien for :
• The operator of the welding machine.
• The personnel of the nal customer responsible for the installaon and
operaon of the machine.
This manual contains informaon on :
• Installaon and connecon.
• Operaon.
• Technical data.
• Spare parts.
• Accessories.
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GENERAL INFORMATION
FURTHER INFORMATION
Should you require addional technical informaon, please contact us
directly (details on page 3) or our local agent / distributor (details of agents
etc. can be obtained from us).
This manual contains important informaon which is a pre-requisite for
safe operaon of the equipment. The operang personnel must be able to
consult this manual. In the interests of safety, make this manual available to
your personnel in good me.
If the equipment is sold / passed on, please hand over this manual to the
new owner. Please immediately inform us of the name and address of the new
owner, in case we need to contact him regarding the safety of the device.
Please read this manual carefully before installaon of the
machine.
Please especially observe the safety instrucons.
Do not use this welding power source for pipe thawing.
This equipment has been tested and approved in accordance with
BS EN 60974-1
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 manual without nocaon.
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INTRODUCTION
INTRODUCTION
The complete range of Taylor Studwelding Systems Capacitor Discharge units are
compact, portable Stud Welding equipment. The units are specically designed to enable a
small diameter range of ferrous and non-ferrous weld studs to be welded to light gauge,
self-nish or pre-coated materials, in most cases with lile or no reverse marking.
The equipment consists of a control unit, a welding pistol and the necessary
interconnecng cables and accessories (see page 6 for the equipment schedule).
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, melng a thin lm 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 against the
work piece. At this point the arc gap between the two components is maintained by a small
pip on the welding face of the stud. On iniaon 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 3-4 milliseconds the stud hits the work piece and the arc is
exnguished. The kinec energy contained in the moving stud and the remaining spring
pressure, forge the molten parts together to form a weld.
Li Gap welding uses a soer spring than contact. This is especially helpful when
welding soer materials e.g. Aluminium as the strong spring in a contact pistol can damage
the pip on the stud aer more than relavely brief contact. Li Gap also uses a solenoid coil
in the pistol. When the trigger is pressed the coil is energised momentarily, liing the stud
away from the work piece to a pre-determined height and releasing, allowing the stud to
accelerate back towards the work piece. The high current pulse iniates on contact and the
weld takes as in contact welding but at a much faster rate (1-2 milliseconds) because of the
acceleraon from the li.
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EQUIPMENT SCHEDULE
EQUIPMENT
No. OFF DESCRIPTION PART No.
1SYSTEM CD MULTIGUN CONTROLLER 99-100-194
ACCESSORIES ( NOT SUPPLIED WITH EQUIPMENT)
No. OFF DESCRIPTION PART No.
1-3CHUCK KEY 79-101-111
1-3CD CONTACT PISTOL 99-100-020
or CD LIFT GAP PISTOL 99-100-023
NOTE! LIFT GAP PISTOLS MUST BE USING A 2 WIRE TRIGGER
WHICH WOULD REQUIRE ALL 4 PINS IN THE CONTROL
PLUG TO BE CONNECTED.
DO NOT USE OLDER 1 WIRE TRIGGER PISTOLS (WHERE PIN
2 IS UN-CONNECTED) AS THIS WILL DAMAGE THE PCB IN
THE CONTROLLER, CAUSING IT TO FAIL.
1EARTH CABLE ASSEMBLY 99-100-125
See pages 34 to 40 of this manual for a selecon of accessories available from
either your local stockist or the manufacturer.
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EXTERIOR FEATURES
FRONT PANEL
VOLTAGE DISPLAY SETTING BUTTON MAINS FUSE
INDICATOR LED’sON/OFF
SWITCH
PISTOL
CONNECTION
PANEL
MODE DISPLAY
EARTH
CONNECTION
ADJUSTER KNOB PANEL
INDICATOR LEDs
READY (GREEN) Indicates that the capacitor bank is charged to the
pre-selected Value and is ready to weld.
CHARGING (YELLOW) Indicates that the unit is in the process of charging the
capacitors to the pre-selected voltage.
RESET (RED) Indicates that the unit safety circuit has tripped. To
reset the unit, switch o the mains switch, wait
between 5 and 30 seconds then switch back on.
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EXTERIOR FEATURES
REAR PANEL
ON / OFF SWITCH
SERIAL/DATA PLATE
COOLING FAN
MAINS INPUT LEAD
IMPORTANT NOTES !
Due to the power requirements and Electromagnec emissions
produced during normal use, this machine must only be operated in
an industrial environment.
This machine is set up to operate on either 115 Volts AC, or 230 Volts
AC. Check the serial plate before plugging into the correct supply.
Never obstruct the ventral or rear panel venlaon holes as this may
cause the unit to overheat during operaon.
Never remove any poron of the unit housing without rst isolang
the unit from the mains electrical supply.
Servicing and maintenance must only be performed by suitably
qualied personnel.
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SAFETY
PROTECT YOURSELF AND OTHERS !
Read and understand these safety noces.
1. ELECTRICAL
No poron of the outer cover of the welding controller should be removed by
anyone other than suitably qualied 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 uids to clean electrical components as these
may penetrate into the electrical system
Installaon must be according to the seng up procedure detailed on
page 12 of this manual and must be in line with naonal, regional and local safety
codes.
2. FIRE
During welding small parcles of very hot metal are expelled. Ensure that no
combusble materials can be ignited by these.
3. LIMITATIONS OF USE
The mass of the welding controller is between 16 and 18.5kg 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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SAFETY
4. 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 protecon.
Fumes and gases can seriously harm your health. Use the equipment only in a
suitably venlated area. If venlaon is inadequate, then appropriate fume
extracon equipment must be used.
Hot metal spaer can cause re and burns. Appropriate clothing must be
worn.
Clothing made from, or soiled with, combusble materials must NOT be worn.
Have a re exnguisher nearby and know how to use it.
Magnec elds from high currents can aect heart pacemakers or other
electronically controlled medical devices. It is imperave 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 electromagnec radiaon, 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.
5. MAINTENANCE
All cables must be inspected regularly to ensure that no danger exists from
worn or damaged insulaon or from unsound electrical connecons. 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.
6. 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.
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