Taylor CD-MULTIGUN Operating Manual
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Taylor CD-MULTIGUN Operating Manual

Compact capacitor discharge studwelding equipment
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TAYLOR STUDWELDING
SYSTEMS LIMITED.
OPERATING GUIDE
FOR
CD-MULTIGUN
COMPACT CAPACITOR DISCHARGE
STUDWELDING EQUIPMENT
VISIT OUR WEBSITE
1
V-21A
A TAYLORMADE CAPACITOR DISCHARGE PRODUCT

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  • Page 1 TAYLOR STUDWELDING SYSTEMS LIMITED. OPERATING GUIDE CD-MULTIGUN COMPACT CAPACITOR DISCHARGE STUDWELDING EQUIPMENT VISIT OUR WEBSITE V-21A A TAYLORMADE CAPACITOR DISCHARGE PRODUCT...

  • Page 2: Table Of Contents

    INDEX PAGE CONTENT GENERAL INFORMATION INTRODUCTION EQUIPMENT SCHEDULE EXTERIOR FEATURES SAFETY SETTING UP AND WELDING WELD SETTINGS LOCATION METHODS WELD ASSESSMENT / TESTING CONTROLLER EXPLOSION AND PARTS LIST CIRCUIT SCHEMATIC EC DECLARATION OF CONFORMITY V-21A...
  • Page 3 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 www.taylor-studwelding.com...

  • Page 4: General Information

    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 notification. V-21A...

  • Page 5: Introduction

    INTRODUCTION INTRODUCTION The complete range of Taylor Studwelding Systems Capacitor Discharge units are compact, portable Stud Welding equipment. 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.

  • Page 6: Equipment Schedule

    EQUIPMENT SCHEDULE EQUIPMENT No. OFF DESCRIPTION PART No. SYSTEM CD MULTIGUN CONTROLLER 99-100-194 ACCESSORIES ( NOT SUPPLIED WITH EQUIPMENT) No. OFF DESCRIPTION PART No. CHUCK KEY 79-101-111 CD CONTACT PISTOL 99-100-020 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.

  • Page 7: Exterior Features

    EXTERIOR FEATURES FRONT PANEL VOLTAGE DISPLAY SETTING BUTTON MAINS FUSE INDICATOR LED’s ON/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.
  • Page 8 EXTERIOR FEATURES REAR PANEL ON / OFF SWITCH SERIAL/DATA PLATE COOLING FAN MAINS INPUT LEAD IMPORTANT NOTES ! Due to the power requirements and Electromagnetic 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.

  • Page 9: Safety

    SAFETY PROTECT YOURSELF AND OTHERS ! Read and understand these safety notices. 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.
  • Page 10 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 protection. Fumes and gases can seriously harm your health. Use the equipment only in a suitably ventilated area.
  • Page 11 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 protection. Fumes and gases can seriously harm your health. Use the equipment only in a suitably ventilated area.

  • Page 12: Setting Up And Welding

    SETTING UP & WELDING SETTING UP & WELDING 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 9 through 11 of this manual.
  • Page 13 SETTING UP & WELDING Select an appropriate pistol for use with your controller. Taylor Studwelding Systems Ltd controllers are designed to operate with a range of appropriate CD welding pistols. Be sure to consult the operating guide accompanying the pistol before connection and use.
  • Page 14 At switch ON the controller will briefly charge to 35V on the VOLTAGE display and the MODE display will read “TAYLOR STUD CD MULTIGUN” Within 5 seconds the MODE display will change to “Welding Mode” and the VOLTAGE display will change to match the voltage shown in the MODE display.
  • Page 15 SETTING UP & WELDING Ensuring that a stud has been loaded, position the stud at the location on the work piece where it is to be welded. Press down firmly on the pistol until all three points of the tripod (or the face of the nose cone if using instead) are firmly in contact with the work piece.
  • Page 16 SETTING UP & WELDING SETTING UP & WELDING A cold stud weld is noticeable by undercutting of the flange and lack of / minimal formation of spatter. A cold weld is usually caused by too little energy and / or too high spring pressure. A hot stud weld is noticeable by excessive spatter formation and partial melting of the flange.

  • Page 17: Weld Settings

    WELD SETTINGS The following pages (18 to 20) detail the suggested settings for the Multigun controller , both Contact & Lift Gap The setting charts were established with the performance of repetitive weld tests using the standard equipment's specified above, studs manufac- tured to the BS EN ISO 13918 standard, in the following materials : Mild Steel, Grade St37-3 Stainless Steel, Grade 1.4303...
  • Page 18 WELD SETTINGS CONTACT LIFT GAP STUD STUD SHEET VOLTAGE SPRING VOLTAGE LIFT DIAMETER MATERIAL MATERIAL SETTING SETTING SETTING SETTING M2.5 St37-3 2½ 2½ S304 2½ 2½ ZINTEC 2½ St37-3 2½ 2½ S304 2½ 2½ ZINTEC 2½ 1.4303 2½ 2½ S304 2½...
  • Page 19 WELD SETTINGS CONTACT LIFT GAP STUD STUD SHEET VOLTAGE SPRING VOLTAGE LIFT DIAMETER MATERIAL MATERIAL SETTING SETTING SETTING SETTING St37-3 2½ 2½ S304 2½ 2½ ZINTEC 2½ 1.4303 2½ 2½ S304 2½ 2½ ZINTEC 2½ AlMg3 St37-3 2½ 2½ S304 2½...
  • Page 20 METHODS OF STUD LOCATION Economic stud location may be obtained using any one of the following methods, depending on the type of work involved :-  Tripod leg assembly.  Nose cone assembly.  Extended leg assembly.  TRIPOD LEG ASSEMBLY. This is generally used for low volume production and one off compo- nents.

  • Page 21: Weld Assessment / Testing

    WELD ASSESSMENT / TESTING Visual examination of weld quality can, even with limited experience, pro- vide 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 after welding should be ensured.
  • Page 22 COMPONENT EXPLOSION CD-MULTIGUN CONTROLLER ITEM QTY. PART No. DESCRIPTION 70-105-282 SIDE PANEL 70-105-281 TOP COVER 70-105-014 HANDLE 70-105-283 SIDE PANEL CAP BANK SEE PAGE 30 BACK PANEL FRONT PANEL PAGE 32 SEE PAGE SPLITTER ASSY SEE PAGE 31 BASEPLATE SEE PAGE 33...
  • Page 23 COMPONENT EXPLOSION CD-MULTIGUN CONTROLLER - FRONT PANEL 9,10 ITEM QTY. PART No. DESCRIPTION 81-113-010 PUSHBUTTON 70-105-125 FUSE 70-102-085 FUSEHOLDER 70-105-270 SWITCH 70-105-291 PANEL OVERLAY 70-105-284 FRONT PANEL 72-102-001 70-105-303 81-104-030 KNOB 81-104-032 KNOB CAP 70-102-025 CONTROL SOCKET 81-106-031 WELDING SOCKET...
  • Page 24 COMPONENT EXPLOSION CD-MULTIGUN CONTROLLER CAPACITOR BANK ASSEMBLY ITEM QTY. PART No. DESCRIPTION 70-106-044 CLAMP PLATE 70-105-133 POSITIVE BUSBAR 70-105-134 NEGATIVE BUSBAR 70-102-046 THYRISTOR 70-102-047 THYRISTOR CLAMP 70-105-266 RESISTOR 70-102-131 DIODE 70-105-040 CAPACITOR 70-105-115 TERMINAL BLOCK 70-105-114 RELAY 70-105-131 MOUNTING BRACKET...
  • Page 25 COMPONENT EXPLOSION CD-MULTIGUN CONTROLLER - SPLITTER ASSEMBLY ITEM QTY. PART No. DESCRIPTION 70-105-287 BUSBAR 70-105-288 BUSBAR 70-105-289 BUSBAR 70-102-100 RECTIFIER 70-105-286 BUSBAR 70-102-047 THYRISTOR CLAMP 70-102-046 THYRISTOR 70-105-306 HEATSINK 81-113-021 MOUNTING PILLAR V-21A...
  • Page 26 COMPONENT EXPLOSION CD-MULTIGUN CONTROLLER - BACK PANEL ITEM QTY. PART No. DESCRIPTION 70-105-285 BACK PANEL 81-120-055 AUXILIARY TRANSFORMER 81-106-081 70-102-225 SERIAL/DATA LABEL 81-104-220 FAN GUARD 70-102-075 MAINS CABLE GLAND V-21A...
  • Page 27 COMPONENT EXPLOSION CD-MULTIGUN CONTROLLER - BASEPLATE ITEM QTY. PART No. DESCRIPTION 70-105-116 RESISTOR 70-105-280 BASEPLATE 81-113-024 FOOT V-21A...

  • Page 28: Circuit Schematic

    CIRCUIT SCHEMATIC V-21A...

  • Page 29: Ec Declaration Of Conformity

    EU DECLARATION OF CONFORMITY Responsible Party Name Taylor Studwelding Systems Ltd Address Commercial Road Dewsbury West Yorkshire WF13 2BD Designation of Product : Studwelding equipment CDM series types CDM8, CDM9, CDM10 Studwelding gun series C1, C2, LG1, LG2 The above mentioned equipment complies with the requirements of the following directives :...

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