Taylor M8 User manual

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

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INDEX
PAGE CONTENT
3GENERAL INFORMATION
5INTRODUCTION
7EXTERNAL FEATURES
9SAFETY NOTES
12 SETTING UP & WELDING
16 WELD SETTINGS
23 METHODS OF STUD LOCATION
24 WELD ASSESSMENT/TESTING
25 CONTROLLER PARTS LISTS & COMPONENT EXPLOSIONS
26 - SUB-ASSEMBLY BREAKDOWN
27 - FRONT PANEL
28 - CAPACITOR BANK
32 - BASEPLATE
35 WIRING SCHEMATICS - STANDARD CONTACT MODELS
36 - LIFT GAP MODELS
37 - CNC CONTACT MODELS
38 - CNC GAP MODELS
39 DECLARATION OF CONFORMITY

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GENERAL INFORMATION
MANUFACTURERS DETAILS
TAYLOR STUDWELDING SYSTEMS LIMITED
COMMERCIAL ROAD
DEWSBURY
WEST YORKSHIRE
WF13 2BD ADD US TO YOUR CONTACTS
ENGLAND
TELEPHONE :[phone]
FACSIMILE :[phone]
e-mail :[e-mail]
TECHNICAL TEL :[phone]
SALES TEL :[phone]
WEB :www.taylor-studwelding.com
FIND US ON GOOGLE MAPS →
PURPOSE AND CONTENT OF THIS MANUAL
This manual has been wrien for :
• The operator of the welding machine.
• The personnel of the nal customer responsible for the installaon and
operaon of the machine.
This manual contains informaon on :
• Installaon and connecon.
• Operaon.
• Technical data.
• Spare parts.
• Accessories.

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GENERAL INFORMATION
FURTHER INFORMATION
Should you require addional technical informaon, please contact us
directly (details on page 3) or our local agent / distributor (details of agents etc. can
be obtained from us).
This manual 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
manual. In the interests of safety, make this manual available to your personnel in
good me.
If the equipment is sold/passed on, please hand over this manual to the new
owner. Please 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 manual carefully before installaon of the
machine.
Please especially observe the safety instrucons.
Do not use this welding power source for pipe thawing.
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 nocaon.

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INTRODUCTION
INTRODUCTION
The complete range of Taylor Studwelding Systems Capacitor Discharge units
are compact, portable Stud Welding equipment. 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 (see page 6 for the equipment schedule).
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 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 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 3-4
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.
Li Gap welding uses a soer spring than contact. This is especially helpful
when welding soer materials e.g. Aluminium as the strong spring in a contact
pistol can damage the pip on the stud aer more than relavely brief contact. Li
Gap also uses a solenoid coil in the pistol. When the trigger is pressed the coil is
energised momentarily, liing the stud away from the work piece to a pre-
determined height and releasing, allowing the stud to accelerate back towards the
work piece. The high current pulse iniates on contact and the weld takes as in
contact welding but at a much faster rate (1-2 milliseconds) because of the
acceleraon from the li.

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EQUIPMENT SCHEDULE
EQUIPMENT
No. OFF DESCRIPTION PART No.
1SYSTEM CD M8 CONTACT 99-100-300
COMPLETE WITH CONTACT PISTOL
& EARTH CABLE ASSEMBLY
or SYSTEM CD M9 CONTACT 99-100-301
COMPLETE WITH CONTACT PISTOL
& EARTH CABLE ASSEMBLY
or SYSTEM CD M10 CONTACT 99-100-302
COMPLETE WITH CONTACT PISTOL
& EARTH CABLE ASSEMBLY
or SYSTEM CD M8 LIFT GAP 99-100-303
COMPLETE WITH LIFT GAP PISTOL
& EARTH CABLE ASSEMBLY
or SYSTEM CD M9 LIFT GAP 99-100-304
COMPLETE WITH LIFT GAP PISTOL
& EARTH CABLE ASSEMBLY
or SYSTEM CD M10 LIFT GAP 99-100-305
COMPLETE WITH LIFT GAP PISTOL
& EARTH CABLE ASSEMBLY
ACCESSORIES (NOT SUPPLIED WITH EQUIPMENT)
See the operang guide accompanying the pistol for a selecon of accessories
available from either your local stockist or the manufacturer.

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EXTERNAL FEATURES
FRONT PANEL
1WELDING VOLTAGE SELECTOR KNOB
2WELDING VOLTAGE DIGITAL DISPLAY
3WELDING EARTH PANEL CONNECTIONS
4WELDING PISTOL PANEL CONNECTION
5WELDING PISTOL CONTROL SOCKET
21
INDICATOR LEDs
1READY (GREEN) Indicates
that the capacitor bank is
charged to the pre-selected
value and is ready to weld.
2CHARGING (YELLOW)
Indicates that the unit is in the
process of charging the
capacitors to the pre-selected
voltage.
3RESET (RED) Indicates
that the unit safety circuit has
tripped. To reset the unit,
switch o the mains switch,
wait between 5 and 30 seconds
then switch back on.
354

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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 Electromagnec emissions produced
during normal use, this machine must only be operated in an industrial
environment.
This machine is set up to operate on either 115 Volts AC, or 230 Volts AC.
Check the serial plate before plugging into the correct supply.
Never obstruct the front, ventral or rear panel venlaon holes 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.
Servicing and maintenance must only be performed by suitably qualied
personnel.

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SAFETY
PROTECT YOURSELF AND OTHERS !
Read and understand these safety noces.
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 12 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. LIMITATIONS OF USE
The mass of the welding controller is between 16 and 18.5kg 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.

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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 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.
5. 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.
6. TRAINING
Use of the equipment must 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.

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SAFETY
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 which 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. Non of the
components used in the manufacture are toxic, carcinogenic or harmful to health.

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SETTING UP & WELDING
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 9 through 11 of
this guide.
Plug the controller into the correct mains
AC supply. The controller is rated for either
230V or 115V, check the rang plate and
ensure that the controller is plugged into
the correct supply before turning the
power on.
Connect the welding earth cables to the
controller socket marked +.
Note that the cable end plug has a peg
which mates with a key slot in the panel
mounted socket.
IMPORTANT ! Secure the connectors with
a clockwise turn unl they lock. Failure to
do this will result in damage to the
connectors 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.

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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 operang guide
accompanying the pistol before connecon
and use.
Connect the welding pistol cable to the
controller socket marked -.
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.
Connect the welding pistol control cable to
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.
Set up the pistol in-line with the operang
instrucons.

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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
sengs.
Ensuring that a stud has been loaded, posion the stud at the locaon on the work
piece where it is to be welded. Press down rmly on the pistol unl all three points
of the tripod (or the face of the nose cone if using instead) are rmly in contact
with the work piece. Do not drape or wrap the pistol cables over or around yourself
whilst operang the equipment. Allow the cables to trail naturally to the oor.
Press the trigger.
Once welding has taken place. Draw the
pistol o the welded stud. Always li the
welding pistol vercally from the welded
stud. Failure to do this may cause damage
to the chuck, which will result in the chuck
and stud arcing together during subsequent
welds and thereby reducing the working life
of the chuck.

V-21A 15
SETTING UP & WELDING
Visually inspect the weld. A good weld will result in an
all round weld with a small visible witness of spaer
surrounding the ange of the stud.
A cold stud weld is noceable by undercung of the
ange and lack of / minimal formaon of spaer. A
cold weld is usually caused by too lile energy and / or
too high spring pressure.
A hot stud weld is noceable by excessive spaer
formaon and paral melng of the ange. A hot weld
is usually caused by too much energy and / or too lile
spring pressure.
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 occur.
Finished studs may be subjected to a bending test to ascertain the
strength of the weld. This may be achieved by placing a bending bar
assembly, ed with the correct nozzle, over the stud and bending
the stud through 30° and then back to the vercal. This test follows
the specicaon of BS EN ISO 14555:2014.
A simpler test may be achieved by bending the stud over 30° using
a hide mallet.

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WELD SETTINGS
The following pages (17 to 22) detail the suggested sengs for the following
models :
M8, M9 & M10 both Contact & Li Gap
The seng charts were established with the performance of repeve weld tests
using the standard equipment's specied above, 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 mm Thick, ZINTEC Coated Mild Steel, Grade CR4
1.6 mm Thick, Aluminium Alloy, Grade HE3, Half Hard
The sengs are given only as a general guide and it is recommended that sample
welds be carried out on your own material, as quality of materials and site
condions may vary from user to user.

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WELD SETTINGS CD-M8
CD-M8 CONTACT CD-M8 LIFT GAP
STUD
DIAMETER
STUD
MATERIAL
SHEET
MATERIAL
VOLTAGE
SETTING
SPRING
SETTING
VOLTAGE
SETTING
LIFT
SETTING
M2.5 St37-3CR4 60 2½ 65 2½
S304 60 2½ 65 2½
ZINTEC 80 2½ 90 2
M3 St37-3CR4 75 2½ 80 2½
S304 75 2½ 80 2½
ZINTEC 100 2½ 110 2
1.4303 CR4 75 2½ 80 2½
S304 75 2½ 80 2½
ZINTEC 100 2½ 110 2
AlMg3 HE3 80 3½ 90 3
M4 St37-3CR4 85 2½ 90 2½
S304 85 2½ 90 2½
ZINTEC 120 2½ 130 2
1.4303 CR4 90 2½ 95 2½
S304 90 2½ 95 2½
ZINTEC 120 2½ 130 2
AlMg3 HE3 90 3½ 100 3
M5 St37-3CR4 105 2½ 110 2½
S304 105 2½ 110 2½
ZINTEC 135 2½ 145 2
1.4303 CR4 110 2½ 115 2½
S304 110 2½ 115 2½
ZINTEC 135 2½ 145 2
AlMg3 HE3 105 3½ 110 3

V-21A 18
WELD SETTINGS CD-M8
CD-M8 CONTACT CD-M8 LIFT GAP
STUD
DIAMETER
STUD
MATERIAL
SHEET
MATERIAL
VOLTAGE
SETTING
SPRING
SETTING
VOLTAGE
SETTING
LIFT
SETTING
M6 St37-3CR4 125 2½ 135 2½
S304 125 2½ 135 2½
ZINTEC 160 2½ 175 2
1.4303 CR4 135 2½ 145 2½
S304 135 2½ 145 2½
ZINTEC 175 2½ 180 2
AlMg3 HE3 180 4135 4
M8 St37-3CR4 180 2½
S304 180 2½
ZINTEC 200 2½
1.4303 CR4 190 2½
S304 190 2½
ZINTEC 200 2½
AlMg3 HE3 195 4
M10 St37-3CR4
S304
ZINTEC
EARTH TAG St37-3CR4 90 2½ 85 2½
S304 95 2½ 95 2½
ZINTEC
AlMg3 HE3 80 3½ 80 3
LARGE
BRACKET
St37-3CR4 110 2½ 130 2½
S304 130 2½ 135 2½
ZINTEC

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WELD SETTINGS CD-M9
CD-M9 CONTACT CD-M9 LIFT GAP
STUD
DIAMETER
STUD
MATERIAL
SHEET
MATERIAL
VOLTAGE
SETTING
SPRING
SETTING
VOLTAGE
SETTING
LIFT
SETTING
M2.5 St37-3CR4 40 2½ 45 2½
S304 40 2½ 45 2½
ZINTEC 60 2½ 70 2
M3 St37-3CR4 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 St37-3CR4 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 St37-3CR4 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

V-21A 20
WELD SETTINGS CD-M9
CD-M9 CONTACT CD-M9 LIFT GAP
STUD
DIAMETER
STUD
MATERIAL
SHEET
MATERIAL
VOLTAGE
SETTING
SPRING
SETTING
VOLTAGE
SETTING
LIFT
SETTING
M6 St37-3CR4 90 2½ 120 2½
S304 90 2½ 120 2½
ZINTEC 140 2½ 160 2
1.4303 CR4 110 2½ 120 2½
S304 110 2½ 120 2½
ZINTEC 140 2½ 160 2
AlMg3 HE3 120 4140 4
M8 St37-3CR4 130 2½ 175 2½
S304 130 2½ 175 2½
ZINTEC 180 2½
1.4303 CR4 160 2½
S304 160 2½
ZINTEC 180 2½
AlMg3 HE3 150 4190 4
M10 St37-3CR4 185 2½
S304 200 2½
ZINTEC 200 2½
EARTH TAG St37-3CR4 80 2½ 70 2½
S304 80 2½ 70 2½
ZINTEC 95 2½ 85 2½
AlMg3 HE3 85 3½ 75 3
LARGE
BRACKET
St37-3CR4 95 2½ 85 2½
S304 95 2½ 85 2½
ZINTEC 110 2½ 95 2½