Taylor C2 Bedienungsanleitung
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TAYLOR STUDWELDING
SYSTEMS LIMITED
OPERATING GUIDE
FOR
CD STUDWELDING PISTOLS
TYPE C2 & LG2
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INDEX
PAGE CONTENT
3GENERAL INFORMATION
4INTRODUCTION
5EXTERNAL FEATURES
6SAFETY
8SETTING UP AND WELDING
14 WELD ASSESSMENT/TESTING
15 METHODS OF STUD LOCATION
16 COMPONENT EXPLOSION AND PARTS LISTING - C2 PISTOL
21 COMPONENT EXPLOSION AND PARTS LISTING - LG2 PISTOL
26 ACCESSORIES
31 EC DECLARATION OF CONFORMITY
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GENERAL INFORMATION
MANUFACTURERS DETAILS
TAYLOR STUDWELDING SYSTEMS LIMITED
COMMERCIAL ROAD FIND US
DEWSBURY ON
WEST YORKSHIRE GOOGLE
WF13 2BD MAPS
ENGLAND
TELEPHONE :+44 (0)1924 452123
FACSIMILE :+44 (0)1924 430059
e-mail :info@taylor-studwelding.com
DIRECT SALES TEL :+44 (0)1924 487701
INTERNET :www.taylor-studwelding.com
PURPOSE AND CONTENT OF THIS GUIDE
This guide has been wrien for :
The operator of the welding machine.
Installaon and maintenance personnel.
Purchasing personnel.
This guide contains informaon on :
Installaon and connecon
Operaon.
Technical data.
Spare parts and Accessories.
FURTHER INFORMATION
Should you require addional technical informaon, please contact us directly (details
above) or our local agent/distributor (details of agents etc. can be obtained from us).
This guide contains important informaon which is a pre-requisite for safe operaon of the
equipment. The operang personnel must be able to consult this guide. In the interests of safety,
make this guide available to your personnel in good me.
If the equipment is sold / passed on, please hand over this guide 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 guide carefully before installaon of the machine.
Please especially observe the safety instrucons.
Taylor Studwelding Systems Limited reserves the right to amend the contents of this manual without nocaon.
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INTRODUCTION
INTRODUCTION
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 typically consists of a control unit, a welding pistol and the necessary
interconnecng 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, melng a thin lm of metal on each surface and the
propelling force closes the gap between the two faces, thus forming a weld.
There are two sub-processes of this type of welding. One is known colloquially as contact,
the other as gap or li gap.
In contact welding the stud to be welded is forced by a strong spring in the pistol 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 weld stud towards the work piece. Within 3 to
4 milliseconds of inialisaon 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 or gap welding diers in that the spring in the pistol is much soer. This is
specically to allow the welding of soer non-ferrous materials where the stronger pistol spring
may cause mechanical damage to the stud pip before the weld can be inialised. The soer
spring however, does not have sucient force to close the gap both quickly and forcefully
enough. Therefore a li gap pistol also contains an electrical solenoid li coil. When the weld is
iniated the li coil briey lis the weld stud away from the work piece to an operator set height.
As the coil releases, the high current pulse from the capacitors is iniated so that upon contact of
the pip to the work piece the weld begins. As the pip vaporises, the momentum of the moving
stud closes the gap quickly and forcefully enough to complete the weld. Usually in under 3
milliseconds. This faster weld is very important as most non-ferrous metals are much beer
thermal conductors and a faster weld ensures that the heat generated in the weld is not
conducted away before the arc gap closes.
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EXTERNAL FEATURES
C2 PISTOL LG2 PISTOL
COMPLETE PISTOL ORDER NUMBER
99-100-010 99-100-011
1 1
2 2
77
3 3
88
4 4
5 5
6 6
1FRONT END CAP ASSEMBLY* 1FRONT END CAP ASSEMBLY*
2CD CHUCK* 2CD CHUCK*
3CHUCK NUT 3CHUCK NUT
4TRIGGER PUSHBUTTON 4TRIGGER PUSHBUTTON
5WELDING PLUG 5WELDING PLUG
6CONTROL PLUG 6CONTROL PLUG
7SPRING PRESSURE ADJUSTER 7LIFT HEIGHT ADJUSTER
8SPRING PRESSURE INDICATOR 8LIFT HEIGHT INDICATOR
*An assortment of alternave front end cap assemblies and chucks are available
for welding dierent sizes of stud and to assist with producon xtures and
templates. These can be found in the ACCESSORIES secon of this guide on
page 26.
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SAFETY
PROTECT YOURSELF AND OTHERS !
These welding pistols whilst unconnected are inert but once connected as part of a
complete welding installaon may present potenal risks and dangers. Please 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.
BEWARE ! 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 in the appropriate
operang/installaon guides for the equipment being used 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. 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 DANGER 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.
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SAFETY
4. 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.
5. TRAINING
Use of the equipment must be limited to authorised personnel only who must be suitably
trained and must have read and understood this and any other applicable documentaon. This
guide must be made available to all operators at all mes and further hard copies of this guide
may be purchased from the manufacturer or downloaded from our website. Measures must be
taken to prevent the use of this equipment by unauthorised personnel. Please note that Taylor
Studwelding Systems Ltd also oer, at an addional cost, personnel training packages, should a
cercate of competency be required for operang/maintenance personnel.
6. 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 operaon. Do not
hang connecng cables over sharp edges and do not install connecng cables near heat sources
or via trac routes where people may trip over them or they may be damaged by the passage of
vehicles (forklis etc.).
7. INTERFERENCE
During welding operaons, intense magnec and electrical elds are unavoidably produced
which may interfere with other sensive Electronic equipment.
All Taylor Studwelding equipment is designed, manufactured and tested to conform the current
appropriate European standards and direcves regarding electromagnec emissions and
immunity and as such is safe to use in any normal environment
8. 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. Non of the components used in the
manufacture are toxic, carcinogenic or harmful to health. Please note that, in line with the WEEE
direcve, Taylor Studwelding Systems Ltd oers a return for disposal policy.
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SETTING UP & WELDING
Select the required weld stud on the basis of diameter,
length and material. See our separate catalogue entled
"Capacitor Discharge Stock list" which can found by scanning
the QR code below or alternavely is available from your
local Taylor stockist.
Select the required CD chuck for the chosen weld stud diameter
(a list of available chucks is shown on page 30 of this guide), insert
the stud to be welded into the chuck and set the stud protrusion
to the dimension shown in the accompanying diagram by
adjusng the backstop screw as shown.
Securely ghten the chuck backstop locking nut to
maintain the required protrusion.
Aer seng the chuck, insert it
into the pistol chuck holder and
push rmly home unl it comes to
a rest.
Tighten the chuck locking nut with
the box spanner provided. Hand
ghtis all that is required. Over
ghtening may result in damage to
your pistol.
1 mm
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SETTING UP & WELDING
At this point the pistol seng method diers dependent on the type of pistol being
used:
SETTING THE C2 TYPE PISTOL
Set the pistol spring pre-load to the
appropriate seng for the stud/
material to be welded. This is
achieved by twisng the rear end
cap adjuster.
The indicator window on the side of
the pistol indicates the seng.
SETTING THE LG2 TYPE PISTOL
The LG2 pistol features an electrical li coil to give a user adjustable li to the stud
to be welded. The following steps
need to be carried out to set the li
required.
Start by adjusng the li to the
maximum posion. This is achieved
by turning the rear end cap adjuster
in an an-clockwise direcon unl
it reaches its end of travel.
Once this is done, you will need to
nd the Zero Li Posion.
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SETTING UP & WELDING
To do this place the pistol into the
welding posion, pressing down on
the pistol unl the stud is pressed
back into the pistol and all three
points of the tripod legs are rmly
in contact with the work surface.
With the pistol held rmly in this
posion. Again turn the rear end
cap adjuster, this me clockwise.
Connue to turn the adjuster unl
it reaches the point in its travel
where it would begin to force the
points of the tripod legs away from the work surface. This is the zero li posion.
The required li can now be set.
This is achieved by once more
turning the rear end cap adjuster in
an an-clockwise direcon. The li
adjuster has a click detent which
clicks every half turn. Each click
(half turn) equates to a 0.5mm
change in li. Therefore a desired
li of 3mm will be achieved by
turning the adjuster an-clockwise
for 6 clicks.
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