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Taylor SYSTEM CD200 SERIES, Operating Manual

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WELD SETTINGS CD200-99 

                                                               CD200-99 CONTACT        CD200-99 GAP 

19 

STUD 

DIAMETER 

STUD 

MATERIAL 

SHEET 

MATERIAL 

VOLTAGE 

SETTING 

SPRING 

SETTING 

VOLTAGE 

SETTING 

LIFT  

SETTING 

M2.5 

St37-3 

CR4 

40 

2½ 

45 

2½ 

 

 

S304 

40 

2½ 

45 

2½ 

 

 

ZINTEC 

60 

2½ 

70 

2 

M3 

St37-3 

CR4 

45 

2½ 

50 

2½ 

 

 

S304 

45 

2½ 

50 

2½ 

 

 

ZINTEC 

75 

2½ 

85 

2 

 

1.4303 

CR4 

45 

2½ 

50 

2½ 

 

 

S304 

45 

2½ 

50 

2½ 

 

 

ZINTEC 

90 

2½ 

100 

2 

 

AlMg3 

HE3 

50 

3½ 

55 

3 

M4 

St37-3 

CR4 

60 

2½ 

65 

2½ 

 

 

S304 

60 

2½ 

65 

2½ 

 

 

ZINTEC 

100 

2½ 

110 

2 

 

1.4303 

CR4 

60 

2½ 

65 

2½ 

 

 

S304 

60 

2½ 

65 

2½ 

 

 

ZINTEC 

100 

2½ 

110 

2 

 

AlMg3 

HE3 

65 

3½ 

70 

3 

M5 

St37-3 

CR4 

75 

2½ 

90 

2½ 

 

 

S304 

75 

2½ 

90 

2½ 

 

 

ZINTEC 

110 

2½ 

125 

2 

 

1.4303 

CR4 

85 

2½ 

95 

2½ 

 

 

S304 

85 

2½ 

95 

2½ 

 

 

ZINTEC 

110 

2½ 

125 

2 

 

AlMg3 

HE3 

80 

3½ 

90 

3 

Summary of Contents for SYSTEM CD200 SERIES

Page 1: ...TAYLOR STUDWELDING SYSTEMS LIMITED OPERATING MANUAL FOR SYSTEM CD200 SERIES COMPACT CAPACITOR DISCHARGE STUDWELDING EQUIPMENT...

Page 2: ...ELDING 16 WELD SETTINGS 27 LOCATION METHODS 28 WELD ASSESSMENT TESTING 29 CONTACT PISTOL EXPLOSION AND PARTS LIST 31 MARK V LIFT GAP PISTOL EXPLOSION AND PARTS LIST 34 CONTROLLER EXPLOSION AND PARTS L...

Page 3: ...taylor studwelding com TECHNICAL TEL 44 0 1924 487703 SALES TEL 44 0 1924 487701 PURPOSE AND CONTENT OF THIS MANUAL This manual has been written for The operator of the welding machine The personnel...

Page 4: ...of the equipment The operating personnel must be able to consult this manual In the interests of safety make this manual available to your personnel in good time If the equipment is sold passed on pl...

Page 5: ...o be welded as they are propelled towards each other The arc pro duced heats the two surfaces melting a thin film of metal on each surface and the propelling force closes the gap between the two faces...

Page 6: ...P 99 100 115 COMPLETE or SYSTEM CD200 132 CONTACT 99 100 119 COMPLETE 1 CD CONTACT PISTOL 99 100 020 or CD LIFT GAP PISTOL 99 100 023 2 EARTH CABLE ASSEMBLY 99 100 031 ACCESSORIES SUPPLIED WITH EQUIPM...

Page 7: ...DICATOR LED s 1 READY GREEN Indicates that the capacitor bank is charged to the pre selected value and is ready to weld 2 CHARGING YELLOW Indicates that the unit is in the process of charging the capa...

Page 8: ...and Electromagnetic emissions produced during normal use this machine must only be operated in an industrial environment This machine will operate from any AC mains supply between 100 and 250 Volts at...

Page 9: ...fatal voltages in this module we do not recommend tampering with the module It can be safely removed and replaced via our factory exchange system BE AWARE Capacitors store electrical energy Check for...

Page 10: ...al devices It is imperative that all personnel likely to come into the vicinity of any welding plant are warned of the possi ble RISK TO LIFE before entering the area 4 MAINTENANCE All cables must be...

Page 11: ...g equipment should be installed at least 5 metres away from any computer equipment to minimise any possible interaction Note that ca bles carrying signals between electronic devices are also capable o...

Page 12: ...ler The IEC supply lead however must be fitted with the appropri ate connector Connect the welding earth cables to the controller Note that the cable end sockets have a key slot to match with the peg...

Page 13: ...ounting socket are keyed to prevent incorrect fitting Push the plug firmly home and twist the locking ring clockwise to secure the plug in position Select the required weld stud on the basis of diame...

Page 14: ...damage to your pistol SETTING THE PISTOL STANDARD CONTACT PISTOL Set the pistol spring preload to the appropriate setting for the welding task to be performed See the tables on pages 16 26 MkV LIFT GA...

Page 15: ...y from the plate The pistol is now in the zero lift position and twisting the rear end cap anti clockwise by one click at a time will increase the lift by 0 25 mm increments see the tables on pages 16...

Page 16: ...ertically from the welded stud Failure to do this may cause the tines of the chuck to splay outwards which will result in the chuck and stud arcing to gether during subsequent welds Visually inspect t...

Page 17: ...e A one sided stud weld arc blow is usually caused by incorrect earthing of the work piece This may be corrected by placing the welding earths opposite each other across the area where the weld is to...

Page 18: ...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 St...

Page 19: ...0 2 M3 St37 3 CR4 75 2 80 2 S304 75 2 80 2 ZINTEC 100 2 110 2 1 4303 CR4 75 2 80 2 S304 75 2 80 2 ZINTEC 100 2 110 2 AlMg3 HE3 80 3 90 3 M4 St37 3 CR4 85 2 90 2 S304 85 2 90 2 ZINTEC 120 2 130 2 1 430...

Page 20: ...2 S304 125 2 135 2 ZINTEC 160 2 175 2 1 4303 CR4 135 2 145 2 S304 135 2 145 2 ZINTEC 175 2 180 2 AlMg3 HE3 180 4 135 4 M8 St37 3 CR4 180 2 S304 180 2 ZINTEC 200 2 1 4303 CR4 190 2 S304 190 2 ZINTEC 2...

Page 21: ...60 2 70 2 M3 St37 3 CR4 45 2 50 2 S304 45 2 50 2 ZINTEC 75 2 85 2 1 4303 CR4 45 2 50 2 S304 45 2 50 2 ZINTEC 90 2 100 2 AlMg3 HE3 50 3 55 3 M4 St37 3 CR4 60 2 65 2 S304 60 2 65 2 ZINTEC 100 2 110 2 1...

Page 22: ...140 2 160 2 1 4303 CR4 110 2 120 2 S304 110 2 120 2 ZINTEC 140 2 160 2 AlMg3 HE3 120 4 140 4 M8 St37 3 CR4 130 2 175 2 S304 130 2 175 2 ZINTEC 180 2 1 4303 CR4 160 2 S304 160 2 ZINTEC 180 2 AlMg3 HE3...

Page 23: ...INTEC 40 2 50 2 M3 St37 3 CR4 25 2 30 2 S304 25 2 30 2 ZINTEC 55 2 65 2 1 4303 CR4 25 2 30 2 S304 25 2 30 2 ZINTEC 70 2 80 2 AlMg3 HE3 30 3 35 3 M4 St37 3 CR4 40 2 45 2 S304 40 2 45 2 ZINTEC 80 2 90 2...

Page 24: ...CR4 80 2 90 2 S304 80 2 90 2 ZINTEC 110 2 130 2 AlMg3 HE3 120 4 120 4 M8 St37 3 CR4 130 2 145 2 S304 130 2 145 2 ZINTEC 150 2 185 3 1 4303 CR4 130 2 175 3 S304 130 2 175 3 ZINTEC 150 2 185 3 AlMg3 HE...

Page 25: ...on Advice on jig manufacture can be obtained from your sales representative EXTENDED LEG ASSEMBLY This is used where a requirement for welding very long studs is neces sary The extended leg assembly a...

Page 26: ...bar This bending bar available from your supplier see the accessories section of this manual fit ted with the correct size of nozzle for the stud to be tested is used to bend over the stud in accordan...

Page 27: ...COMPONENT EXPLOSION STANDARD CONTACT PISTOL 25 1 2 3 4 5 6 7 8 9 10 11 12 15 16 17 13 14 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32...

Page 28: ...01 024 SHAFT KEY 14 1 71 101 028 TRIGGER MICRO SWITCH 15 1 71 101 042 COPPER FERRULE 16 1 71 101 034 WELD CABLE SUPPORT SLEEVE 17 1 71 101 033 CONTROL CABLE SUPPORT SLEEVE 18 1 71 101 009 SPRING CONTA...

Page 29: ...COMPONENT EXPLOSION MARK V LIFT GAP PISTOL 27 1 2 3 4 5 6 7 8 9 12 11 10 13 14 15 16 17 40 41 42 43 44 45 46 47 48 49 50 51 52 53 31 32 33 34 35 36 37 38 39 18 19 20 21 22 23 24 25 26 27 28 29 30...

Page 30: ...OL BODY MOULDING 2 PARTS 12 1 71 102 070 LIFT INDICATION DECAL 13 1 71 102 065 COIL ADJUSTOR 14 1 71 102 064 COIL MOUNTING CUP 15 4 Z205 03 006 BUSH RETAINING SCREW 16 2 Z230 06 958 PISTOL BODY SCREW...

Page 31: ...1 71 102 029 CABLE DOWEL 37 1 71 101 011 SHAFT CIRCLIP 38 2 71 101 007 LINER DOWEL 39 1 71 102 074 SPRING 40 1 71 102 068 LINER SLEEVE 41 2 ZZ100 03 004 SCREW 42 1 71 101 004 BELLOWS RETAINER 43 1 71...

Page 32: ...COMPONENT EXPLOSION CD200 SERIES CONTROLLER 30 1 2 3 4 5 6 7 8 9 15 14 13 12 11 10 29 28 27 26 25 24 23 16 17 18 19 20 21 22...

Page 33: ...6 1 70 105 021 POWER SUPPLY MODULE CONTACT MODELS ONLY 7 1 70 105 019 POSITIVE CONNECTION CABLE 8 1 70 105 018 MOUNTING PILLAR 9 1 70 102 046 WELDING THYRISTOR 10 1 70 102 047 THYRISTOR BOX CLAMP 11 1...

Page 34: ...1 70 105 002 HOUSING BASEPLATE 24 1 70 105 013 BALLAST RESISTOR 25 1 70 105 020 NEGATIVE CONNECTION CABLE 26 1 70 105 005 CAPACITOR MOUNTING BLOCK 27 1 70 105 006 THYRISTOR MOUNTING PLATE 28 2 70 105...

Page 35: ...RIBBON CABLE POWER SUPPLY UNIT DANGER HIGH VOLTAGE ENCLOSURE CONTAINS NO USER SERVICE ABLE PARTS ORANGE PURPLE BLACK GREEN WHITE BLACK RED BROKEN LINE INDICATES LIFT GAP CONTROLLER ONLY FLYBACK DIODE...

Page 36: ...OD LEG STANDARD 79 101 052 or 3 TRIPOD LEG LONG SEE NOTE 79 101 054 2 1 FRONT END CAP 79 101 051 3 2 GRUB SCREW Z400 05 004 SLIMLINE TRIPOD LEG ASSEMBLY 3 2 1 COMPLETE ASSEMBLY AVAILABLE UNDER PART NU...

Page 37: ...101 069 22 mm ASSY 79 101 068 4 5 ITEM QTY DESCRIPTION PART No 1 1 30 mm NOSE CONE 79 101 072 or 1 22 mm NOSE CONE 79 101 078 or 1 25 4 mm NOSE CONE 79 101 077 2 1 FRONT END CAP 79 101 051 3 2 GRUB SC...

Page 38: ...FIT CHUCKS WITH 12 mm LONG BACKSTOP 79 101 071 2 LOCKING NUTS ITEM QTY DESCRIPTION PART No 1 1 30 mm SCREW IN NOSE CONE 79 101 086 or 1 22 mm SCREW IN NOSE CONE 79 101 084 or 1 25 4 mm SCREW IN NOSE...

Page 39: ...QTY DESCRIPTION PART No 1 2 EXTENDED LEG 81 101 004 2 2 GRUB SCREW Z430 05 006 3 2 PIVOTAL GRIP INSERT 79 101 142 4 2 GRUB SCREW Z400 05 004 5 1 FRONT END CAP 79 101 141 6 1 CENTRING GUIDE 3 mm 79 10...

Page 40: ...CENTRING DEVICE 1 2 COMPLETE ASSEMBLIES AVAILABLE UNDER PART NUMBERS 22 CUP ROD 79 101 112 25 4 1 CUP ROD 79 101 113 30 CUP ROD 79 101 114 ITEM QTY DESCRIPTION PART No 1 1 30 mm CENTRING CUP 79 101 11...

Page 41: ...4 AVAILABLE UNDER PART NUMBER 79 101 120 1 5 6 7 ITEM QTY DESCRIPTION PART No 1 1 BENDING BAR 79 101 121 2 1 M10 NOZZLE 79 101 128 3 1 M8 NOZZLE 79 101 127 4 1 M6 NOZZLE 79 101 126 5 1 M5 NOZZLE 79 1...

Page 42: ...79 101 022 STANDARD CD CHUCK WITH BACKSTOP PART No s M2 5 79 101 002 M3 79 101 003 M4 79 101 004 M5 79 101 005 M6 79 101 006 M7 1 79 101 007 M8 79 101 008 STANDARD M10 CHUCK WITH BACKSTOP PART No 79 1...

Page 43: ...or Studwelding Systems Ltd DESCRIPTION OF MACHINE Capacitor Discharge Studwelding Equipment TYPE CD200 PART NUMBER Applicable EC guidelines and corresponding standards Low voltage guideline 73 23 EEC...

Page 44: ...EMC CERTIFICATE 42...

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