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V

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21A

GUIDE TO EXTERNAL FEATURES

9

BACK PANEL

1. RATING/SERIAL PLATE

4. MAIN FUSE

2. ON/OFF SWITCH

5. MAINS INLET

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IEC SOCKET OR

3. VENTILLATION FAN/GRILLE

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! 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.

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Summary of Contents for CD-i

Page 1: ...V 21A TAYLOR STUDWELDING SYSTEMS LIMITED OPERATING GUIDE FOR TYPE CD i CAPACITOR DISCHARGE STUDWELDING EQUIPMENT A TAYLORMADE CAPACITOR DISCHARGE STUDWELDING SYSTEM ...

Page 2: ...RMATION 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 ...

Page 3: ... 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 Insta...

Page 4: ...form 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 100 250...

Page 5: ... 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 wi...

Page 6: ...ken 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 tr...

Page 7: ...ed 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 o...

Page 8: ...T 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 ...

Page 9: ...ns 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 ho...

Page 10: ...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...

Page 11: ...t 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 ...

Page 12: ...e 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 tes...

Page 13: ...5 2 35 2 AL 80 2 50 2 35 2 M4 MS 85 2 60 2 40 2 SS 85 2 60 2 40 2 AL 90 3 65 3 45 3 M5 MS 105 2 75 2 65 2 SS 110 2 85 2 65 2 AL 110 3 80 3 70 3 M6 MS 125 2 90 2 80 2 SS 135 2 110 2 80 2 AL 180 4 120 4 120 4 M8 MS 180 3 130 3 130 3 SS 190 3 160 3 130 3 AL NR 4 150 4 160 4 M10 MS NR 3 185 3 155 3 SS NR 3 NR 3 170 3 ETAG MS 100 2 75 2 65 2 ...

Page 14: ...f 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 r...

Page 15: ...FF 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 ...

Page 16: ...V 21A PARTS LIST EXPLODED DIAGRAMS 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 ...

Page 17: ...3 010 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 ...

Page 18: ...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 GROU...

Page 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 ...

Page 20: ...05 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 ...

Page 21: ...ASHER 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 ...

Page 22: ...V 21A CIRCUIT SCHEMATIC WIRING 22 ...

Page 23: ...romagnetic 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 s...

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