Taylor M8 Operating Manual
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Taylor M8 Operating Manual

Compact capacitor discharge studwelding equipment
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TAYLOR STUDWELDING
SYSTEMS LIMITED
OPERATING GUIDE
FOR
CD-M RANGE
OF
COMPACT CAPACITOR DISCHARGE
STUDWELDING EQUIPMENT
MODELS
M8, M9 & M10
VISIT OUR WEBSITE
V-21A
1

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  • Page 1 TAYLOR STUDWELDING SYSTEMS LIMITED OPERATING GUIDE CD-M RANGE COMPACT CAPACITOR DISCHARGE STUDWELDING EQUIPMENT MODELS M8, M9 & M10 VISIT OUR WEBSITE V-21A...

  • Page 2: Table Of Contents

    INDEX PAGE CONTENT GENERAL INFORMATION INTRODUCTION EXTERNAL FEATURES SAFETY NOTES SETTING UP & WELDING WELD SETTINGS METHODS OF STUD LOCATION WELD ASSESSMENT/TESTING CONTROLLER PARTS LISTS & COMPONENT EXPLOSIONS 26 - SUB-ASSEMBLY BREAKDOWN 27 - FRONT PANEL 28 - CAPACITOR BANK 32 - BASEPLATE WIRING SCHEMATICS - STANDARD CONTACT MODELS 36 - LIFT GAP MODELS...

  • Page 3: General Information

    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 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 COMPLETE WITH CONTACT PISTOL & EARTH CABLE ASSEMBLY SYSTEM CD M10 CONTACT 99-100-302 COMPLETE WITH CONTACT PISTOL & EARTH CABLE ASSEMBLY SYSTEM CD M8 LIFT GAP 99-100-303 COMPLETE WITH LIFT GAP PISTOL & EARTH CABLE ASSEMBLY SYSTEM CD M9 LIFT GAP 99-100-304 COMPLETE WITH LIFT GAP PISTOL &...

  • Page 7: External Features

    EXTERNAL FEATURES FRONT PANEL WELDING VOLTAGE SELECTOR KNOB WELDING VOLTAGE DIGITAL DISPLAY WELDING EARTH PANEL CONNECTIONS WELDING PISTOL PANEL CONNECTION WELDING PISTOL CONTROL SOCKET 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...
  • Page 8 EXTERNAL FEATURES REAR PANEL CARRYING HANDLE SERIAL/DATA LABEL ELECTRICAL SAFETY LABEL ON/OFF SWITCH READ MANUAL LABEL MAINS FUSEHOLDER FUSE RATING LABEL MAINS CABLE GLAND MAINS VOLTAGE LABEL COOLING FAN (DO NOT OBSTRUCT) IMPORTANT NOTES ! Due to the power requirements and Electromagnetic emissions produced during normal use, this machine must only be operated in an industrial environment.
  • Page 9 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 During welding operations, intense magnetic and electrical fields are unavoidably produced which may interfere with other sensitive Electronic equipment. All Taylor Studwelding equipment is designed, manufactured and tested to conform the current appropriate European standards and directives regarding electromagnetic emissions and immunity and as such is safe to use in any normal environment 9.

  • Page 12: 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 guide.
  • 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 SETTING UP & WELDING Switch the controller ON. Select the required welding voltage by turning the selector knob. The voltage is adjustable between 35 and 200 volts in 1 volt steps. See pages 16 to 22 of this guide for suggested settings.
  • Page 15 SETTING UP & WELDING Visually inspect the weld. A good weld will result in an all round weld with a small visible witness of spatter surrounding the flange of the stud. A cold stud weld is noticeable by undercutting of the flange and lack of / minimal formation of spatter.

  • Page 16: Weld Settings

    WELD SETTINGS The following pages (17 to 22) detail the suggested settings for the following models : M8, M9 & M10 both Contact & Lift Gap The setting charts were established with the performance of repetitive weld tests using the standard equipment's specified above, studs manufactured to the BS EN...
  • Page 17 WELD SETTINGS CD-M8 CD-M8 CONTACT CD-M8 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...
  • Page 18 WELD SETTINGS CD-M8 CD-M8 CONTACT CD-M8 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...
  • Page 19 WELD SETTINGS CD-M9 CD-M9 CONTACT CD-M9 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...
  • Page 20 WELD SETTINGS CD-M9 CD-M9 CONTACT CD-M9 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...
  • Page 21 WELD SETTINGS CD-M10 CD-M10 CONTACT CD-M10 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...
  • Page 22 WELD SETTINGS CD-M10 CD-M10 CONTACT CD-M10 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...

  • Page 23: Methods Of Stud Location

    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 components.

  • Page 24: Weld Assessment/Testing

    WELD ASSESSMENT/TESTING Visual examination of weld quality can, even with limited experience, provide 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. Poor welds are indicated by excess metal on one side of the welded flange and / or the presence of an undercut or non-fused area between the stud flange and the parent sheet or plate.
  • Page 25 COMPONENT EXPLOSION CD-M CONTROLLERS (MODELS M8, M9 & M10) ITEM QTY. PART No. DESCRIPTION 70-105-135 HOUSING COVER 70-105-014 CARRYING HANDLE Z100-08-030 SCREW 98-103-051 WARNING LABEL Z200-05-008 SCREW 70-105-297 IDENTIFICATION STICKER (M10 MODEL) 70-105-298 IDENTIFICATION STICKER (M8 MODEL) 70-105-299 IDENTIFICATION STICKER (M9 MODEL)
  • Page 26 COMPONENT EXPLOSION SEE PAGES 28 TO 31 FOR PARTS SEE PAGES 32 TO 34 FOR PARTS BREAKDOWN OF CAPACITOR BREAKDOWN OF BASEPLATE BANK SEE PAGE 27 FOR PARTS BREAKDOWN OF FRONT PANEL ITEM QTY. PART No. DESCRIPTION Z625-04-000 WASHER Z100-04-010 SCREW Z600-05-000 WASHER...

  • Page 27: Front Panel

    COMPONENT EXPLOSION 1, 2, 3 ITEM QTY. PART No. DESCRIPTION 81-104-030 KNOB 81-104-031 POINTER 81-104-032 70-105-118 OVERLAY 70-105-132 FRONT PANEL 70-105-300 PCB (CONTACT MODELS) 70-105-301 PCB (CNC MODELS) 70-105-302 PCB (LIFT GAP MODELS) Z610-03-000 WASHER Z200-03-005 SCREW V-21A...
  • Page 28 COMPONENT EXPLOSION V-21A...
  • Page 29 Z510-10-000 LOCKNUT Z650-10-000 NYLON DOMENUT 70-105-138 INTERNAL CABLE - PISTOL QUANTITY VARIES BY MODEL. M8 = 4 M9 = 6 M10 = 8 QUANTITY VARIES BY MODEL. M8 = 2 M9 = 3 M10 = 3 DIODE c/w NUT & WASHERS...
  • Page 30 COMPONENT EXPLOSION V-21A...
  • Page 31 SCREW 70-105-114 RELAY Z200-05-008 SCREW 70-105-113 TRANSFORMER Z505-08-000 Z615-08-000 WASHER Z600-08-040 WASHER 70-105-259 INSULATIVE WASHER Z510-12-000 LOCKNUT 98-103-062 VOLTAGE LABEL 70-102-080 TRIAC Z200-04-008 SCREW 70-102-100 RECTIFIER QUANTITY VARIES BY MODEL. M8 = 2 M9 = 3 M10 = 4 V-21A...

  • Page 32: Baseplate

    COMPONENT EXPLOSION ITEM QTY. PART No. DESCRIPTION 81-106-031 SOCKET Z200-03-010 SCREW 70-102-025 SOCKET 70-105-130 BASEPLATE 50 x 70 x 5mm SPONGE PAD 70-105-190 EARTH BLOCK Z120-04-018 SCREW 81-106-262 EARTH POINT LABEL 70-105-192 THERMAL TRIP SWITCH Z600-03-000 WASHER Z200-03-005 SCREW Z600-06-025 WASHER 70-105-191 TRIP MOUNTING PLATE...
  • Page 33 COMPONENT EXPLOSION ITEM QTY. PART No. DESCRIPTION Z200-05-012 SCREW Z650-03-000 RIVET 70-105-141 SERIAL/DATA LABEL 70-105-124 98-103-052 HAZARD WARNING LABEL 70-102-018 FAN FINGER GUARD V-21A...
  • Page 34 COMPONENT EXPLOSION ITEM QTY. PART No. DESCRIPTION 98-103-055 SAFETY LABEL 70-105-270 SWITCH 70-102-085 FUSEHOLDER 98-103-063 ADVISORY LABEL 98-103-065 ADVISORY LABEL WARNING/ADVISORY LABEL 70-102-075 CABLE GLAND 70-105-125 FUSE DEPENDS ON MAINS VOLTAGE 98-103-053 115V AC or 98-103-054 230V AC AN APPROPRIATE MAINS CORDSET (NOT PICTURED) WILL BE FITTED DEPENDING ON VOLTAGE/DESTINATION OF CONTROLLER.
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  • Page 39: 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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