Taylor CD-i User manual

V-21A
TAYLOR
STUDWELDING
SYSTEMS LIMITED
OPERATING GUIDE
FOR
TYPE CD-i
CAPACITOR DISCHARGE
STUDWELDING EQUIPMENT
A TAYLORMADE CAPACITOR DISCHARGE STUDWELDING SYSTEM

V-21A
INDEX
2
PAGE No. CONTENT
3USEFUL INFORMATION.
5IMPORTANT SAFETY INFORMATION.
7INTRODUCTION TO STUDWELDING.
8GUIDE 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.

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USEFUL INFORMATION
3
MANUFACTURERS DETAILS
TAYLOR STUDWELDING SYSTEMS LIMITED
COMMERCIAL ROAD
DEWSBURY
WEST YORKSHIRE
WF13 2BD
ENGLAND
TELEPHONE :[phone]
FACSIMILE :[phone]
email :[e-mail]
WEB :www.taylor-studwelding.com
SALES DIRECT TEL :[phone]
TECHNICAL HELPLINE :[phone]
You may wish to record the details of your controller below as this informaon will help
with any technical assistance you may require:
PURPOSE AND CONTENT OF THIS GUIDE
This guide has been wrien for :
• The personnel of the end-user responsible for the installaon and maintenance of the
controller.
• The operator of the welding controller.
This guide contains informaon relang to :
• Installaon and connecon.
• Operaon.
• Technical specicaons and parameters.
• Spare parts.
CONTROLLER SERIAL No.
DATE PURCHASED.

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USEFUL INFORMATION
4
FURTHER INFORMATION
Should you require addional technical informaon, please contact us directly (details
on previous page) or our local agent / distributor (details of agents etc. can be obtained
from us).
This guide contains important informaon which is a pre-requisite for safe Operaon
of the equipment. The operang personnel must be able to consult this guide when
necessary. 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 manual to the new owner
and if possible please inform 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 100-250V AC @ 50Hz
NEVER REMOVE ANY PORTION OF THE UNIT HOUSING WITHOUT FIRST
ISOLATING THE CONTROLLER FROM THE MAINS ELECTRICAL SUPPLY.
NEVER OBSTRUCT THE UNDERSIDE, FRONT OR REAR PANELS AS THIS MAY
CAUSE THE UNIT TO OVERHEAT DURING OPERATION.
DO NOT USE THIS WELDING POWER SOURCE FOR PIPE THAWING.
Taylor Studwelding Systems Limited reserves the right to amend the contents of this guide without nocaon.

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IMPORTANT SAFETY INFORMATION !
5
PROTECT YOURSELF AND OTHERS !
Read and understand these safety notes.
1. ELECTRICAL
No poron of the outer cover of the welding controller should be removed by anyone other
than suitably qualied personnel and never whilst mains power is connected. ALWAYS
disconnect the mains plug from the socket.
BE AWARE ! 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
Installaon must be according to the seng up procedure detailed on page 10 of this
manual and must be in line with naonal, regional and local safety codes.
2. FIRE
During welding small parcles of very hot metal are expelled. Ensure that no combusble
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 protecon.
Fumes and gases can seriously harm your health. Use the equipment only in a suitably
venlated area. If venlaon is inadequate, then appropriate fume extracon equipment
must be used.
Hot metal spaer can cause re and burns. Appropriate clothing must be worn. Clothing
made from, or soiled with, combusble materials must NOT be worn.
Have a re exnguisher nearby and know how to use it.
Magnec elds from high currents can aect heart pacemakers or other electronically
controlled medical devices. It is imperave that all personnel likely to come into the vicinity
of any welding plant are warned of the possible risks before entering the area.
To minimise the risks of exposure to electromagnec radiaon, 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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IMPORTANT SAFETY INFORMATION !
6
4. MAINTENANCE
All cables must be inspected regularly to ensure that no danger exists from worn or
damaged insulaon or from unsound electrical connecons. 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. LIMITATIONS OF USE
The mass of the welding controller is between 11 and 13.3kg dependant on the model
purchased and as such is suitable to be manhandled. The controller is not suitable for use in
rain or snow or in an environment with increased risk of electric shock.
6. TRAINING
Use of the equipment must be limited to authorised personnel only who must be suitably
trained and must have read and understood this manual. This manual must be made
available to all operators at all mes. Further copies of this manual may be purchased from
the manufacturer. Measures must be taken 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 operaon.
Do not hang connecng cables over sharp edges and do not install connecng cables near
heat sources or via trac routes where people may trip over them or they may be
damaged by the passage of vehicles (forklis etc.)
8. INTERFERENCE
During welding operaons, intense magnec and electrical elds are unavoidably produced
and these may interfere with other sensive Electronic equipment.
All Taylor Studwelding equipment is designed, manufactured and tested to conform the
current appropriate European standards and direcves regarding electromagnec
emissions and immunity and as such is safe to use in any normal environment.
9. 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. None of the components used in
the manufacture are toxic, carcinogenic or harmful to health in their “as supplied”
condion.

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INTRODUCTION TO STUDWELDING
7
INTRODUCTION
The complete range of Taylor Studwelding Systems Capacitor Discharge units are
compact, portable Stud Welding equipment's. The units are specically 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 lile or no reverse marking.
The equipment consists of a control unit, a welding pistol and the necessary
interconnecng 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, melng a thin lm 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 of the stud. On iniaon 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 stud towards the work piece. Within 3
to 4 milliseconds the stud hits the work piece and the arc is exnguished. The kinec
energy contained in the moving stud and the remaining spring pressure, forge the molten
parts together to form a weld.

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GUIDE TO EXTERNAL FEATURES
8
FRONT PANEL
1. CARRYING HANDLE
2. WELDING VOLTAGE DISPLAY
3. WELDING VOLTAGE CONTROL KNOB
4. VENTILLATION HOLES ! DO NOT OBSTRUCT !
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

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GUIDE TO EXTERNAL FEATURES
9
BACK PANEL
1. RATING/SERIAL PLATE 4. MAIN FUSE
2. ON/OFF SWITCH 5. MAINS INLET - IEC SOCKET OR
3. VENTILLATION FAN/GRILLE - ! DO NOT OBSTRUCT ! FIXED CABLE (SEE INSET)
OPTIONS AVAILABLE
IMPORTANT NOTES !
Due to the power requirements and Electromagnec 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 venlaon holes or the underside of the unit as this may cause
the unit to overheat during operaon.
Never remove any poron of the unit housing without rst isolang the unit from the mains electrical
supply.
1
2
3
4
5

V-21A
SETTING UP AND WELDING
10
Set up the control unit at the place of work,
ensuring that the mains switch is in the OFF
posion. Ensure that this is done in line with the
notes and safety recommendaons on pages 5 and
6 of this manual.
Plug the controller into the
correct mains AC supply. The
controller is rated for any single
phase AC voltage between 100
and 250VAC at 50Hz. Ensure
the correct plug is ed for
your supply in line with local/
naonal codes.
Connect the welding earth cable to the controller panel
mounted plug.
Note that the cable end plug has a peg which mates with a
key slot in the panel mounted socket.
IMPORTANT !
Secure the connector with a
clockwise turn unl it locks.
Failure to do this will result in
damage to the connector
during welding.
Aach 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 ng 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 connecon and poor results. Where possible, route
the earth cables away from the operator to prevent the operator being posioned between
the run of the cables whilst operang the equipment.
Connect the welding pistol cable to the controller panel
mounted socket.
Note that the cable end plug has a peg which mates with
a key slot in the panel mounted socket.
IMPORTANT !
Secure the connector with
a clockwise turn unl it
locks. Failure to do this
will result in damage to
the connector during

V-21A
SETTING UP AND WELDING
11
Connect the welding pistol control cable to the
panel mounted socket on the controller.
Note that the cable end plug and panel mounng
socket are keyed to prevent incorrect ng. Push
the plug rmly home and twist the locking ring
clockwise to secure the plug in posion.
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 informaon on :
• Pistol Setup
• Spare Parts
• Accessories
• Safety

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WELD SETTINGS
12
This page and the following are intended as a guide to seng your machine.
The sengs outlined in the table are only intended as a starng point. It is possible that the
sengs will give sasfactory results without adjustment, but in reality the quality of the
welding results is governed by many variable factors. These include, most obviously, the
welding power and pistol spring pressure as covered in the table, but can also include
factors such as stud and work-piece material type and condion, ambient temperature,
relave 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 condions and environment. This will enable you to alter the sengs, where
necessary, to achieve welds that are most acceptable to you.
The seng charts were established with the performance of repeve weld tests using
studs manufactured to the BS EN ISO 13918 standard, 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, Stainless Steel, Type S304
1.6 mm Thick, Aluminium Alloy, Grade HE30, Half Hard
N.R. = NOT RECOMMENDED

V-21A
WELD SETTINGS
13
i8 i8 i9 i9 i10 i10
STUD Ø STUD M VOLTAGE SPRING VOLTAGE SPRING VOLTAGE SPRING
M2.5/M3 MS 75 2½ 45 2½ 35 2½
SS 75 2½ 45 2½ 35 2½
AL 80 2½ 50 2½ 35 2½
M4 MS 85 2½ 60 2½ 40 2½
SS 85 2½ 60 2½ 40 2½
AL 90 3½ 65 3½ 45 3½
M5 MS 105 2½ 75 2½ 65 2½
SS 110 2½ 85 2½ 65 2½
AL 110 3½ 80 3½ 70 3½
M6 MS 125 2½ 90 2½ 80 2½
SS 135 2½ 110 2½ 80 2½
AL 180 4120 4120 4
M8 MS 180 3½ 130 3½ 130 3½
SS 190 3½ 160 3½ 130 3½
AL NR 4150 4160 4
M10 MS NR 3½ 185 3½ 155 3½
SS NR 3½ NR 3½ 170 3½
ETAG MS 100 2½ 75 2½ 65 2½

V-21A
WELD TESTING
14
Visual examinaon 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 ange aer welding should be ensured. Poor welds are
indicated by excess metal on one side of the welded ange and / or the presence of an
undercut or non-fused area between the stud ange and the parent sheet or plate.
Incorrect sengs, adverse magnec eects etc. such as those at edge welding posions or
with unbalanced earths and studs welded to the work piece at an angle, the controller and
pistol should be examined with a view to correcng such defects.
MECHANICAL TESTS :
1. BENDING.
The most easily applied method of tesng the quality of welded fasteners considered here,
involves the use of a bending bar. This bending bar (available from your supplier, see the
accessories secon of this manual) ed 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
specicaon.
2. TORSION.
A torsion test provides useful informaon for threaded fasteners. This involves ghtening a
nut on the stud against a spacer, suitably relieved to cater for the ange and weld spaer.
For quantave assessments a suitably calibrated torque wrench may be used, but at its
simplest, a spanner will suce.
In the above tests the performance of the welded joint should be considered in relaon to
the thickness of the material to which the stud is welded. On thicker materials, a full
strength weld is denoted by deformaon or failure of the stud shank. On lighter gauge
material, severe "dimpling" or "dishing" at the reverse to the weld side normally indicates
sucient strength, whilst in most cases, the tearing of a slug of material from the parent
sheet will occur.

V-21A
PARTS LIST & EXPLODED DIAGRAMS
15
1234
5
6
ITEM No. OFF PART No. DESCRIPTION
110 Z200-05-008 SCREW
2170-105-014 HANDLE
32Z105-08-025 SCREW
4170-105-237 LOGO STICKER
5170-105-230 COVER
61SEE 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

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

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PARTS LIST & EXPLODED DIAGRAMS
17
ITEM No. OFF PART No. DESCRIPTION
1181-104-030 KNOB
2181-104-032 KNOB CAP
32Z200-03-010 SCREW
4170-102-025 PANEL CONTROL SOCKET
5170-105-231 CONTROL PANEL OVERLAY
6170-105-227 BASEPLATE
74Z200-03-006 SCREW
84Z610-03-000 WASHER
9170-105-220 DISPLAY PCB
10 281-106-031 PANEL WELD SOCKET
11 170-105-232 SOCKET PANEL OVERLAY
12 470-102-002 FOOT
13 4Z100-04-016 SCREW
4 5 6 7
3 8
1,2 9
10 11 12 13

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PARTS LIST & EXPLODED DIAGRAMS
18
ITEM No. OFF PART No. DESCRIPTION
1170-105-294 FAN
2170-105-229 BACK PANEL
3170-105-142 SERIAL/RATING PLATE
4170-102-018 FAN GUARD
5170-105-270 ON/OFF SWITCH
64Z650-03-000 RIVET
74Z200-05-012 SCREW
8170-102-085 FUSEHOLDER
9170-105-236 FUSE
10 170-105-249 IEC INLET
11 2Z200-05-008 SCREW
12 170-105-248 ADAPTER PLATE (OPTIONAL INSTEAD OF IEC INLET)
13 170-102-075 CABLE GLAND (OPTIONAL INSTEAD OF IEC INLET)
12345
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 GROUNDED PLUG TO IEC
70-102-015 UK BS1363 PLUG TO STRIPPED ENDS
70-102-222 EURO SCHUKO CEE7/7 PLUG TO STRIPPED ENDS

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PARTS LIST & EXPLODED DIAGRAMS
19
ITEM No. OFF PART No. DESCRIPTION
1170-105-221 MAIN PCB
25Z600-03-000 WASHER
35Z200-03-006 SCREW
4570-105-228 MOUNTING PILLAR
5170-105-226 WARNING STICKER
6170-105-219 RESISTOR
7170-105-245 WIRING HARNESS (NOT SHOWN)
123
45
6

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PARTS LIST & EXPLODED DIAGRAMS
20
ITEM No. OFF PART No. DESCRIPTION
11Z200-05-008 SCREW
21NA DIODE LEAD
32Z605-10-000 WASHER
4170-105-225 SOCKET LINK BAR
52Z510-10-000 LOCKNUT
64Z105-05-045 SCREW
75Z615-05-000 SPRING WASHER
85Z600-05-000 WASHER
9170-105-224 POSITIVE BUSBAR
10 470-105-139 CAPACITOR SCREW
11 4Z605-05-999 WASHER
12 4Z615-05-000 SPRING WASHER
13 4Z515-05-000 NUT
14 #70-102-131 DIODE - # NOTE. 2 OFF IN i8, 3 OFF IN i9 & i10 MODELS
15 170-102-047 THYRISTOR CLAMP
16 170-102-046 THYRISTOR
17 170-106-044 CLAMP PLATE
13
12
11
10
6789
12345
14 15 16 17