Taylor C2 User manual

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TAYLOR STUDWELDING
SYSTEMS LIMITED
OPERATING GUIDE
FOR
CD STUDWELDING PISTOLS
TYPE C2 & LG2

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2
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 :[phone]
FACSIMILE :[phone]
e-mail :[e-mail]
DIRECT SALES TEL :[phone]
INTERNET :www.taylor-studwelding.com
PURPOSE AND CONTENT OF THIS GUIDE
This guide has been wrien for :
The operator of the welding machine.
Installaon and maintenance personnel.
Purchasing personnel.
This guide contains informaon on :
Installaon and connecon
Operaon.
Technical data.
Spare parts and Accessories.
FURTHER INFORMATION
Should you require addional technical informaon, please contact us directly (details
above) 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. 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 installaon of the machine.
Please especially observe the safety instrucons.
Taylor Studwelding Systems Limited reserves the right to amend the contents of this manual without nocaon.

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INTRODUCTION
INTRODUCTION
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 typically 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.
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 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 weld stud towards the work piece. Within 3 to
4 milliseconds of inialisaon 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 or gap welding diers in that the spring in the pistol is much soer. This is
specically to allow the welding of soer non-ferrous materials where the stronger pistol spring
may cause mechanical damage to the stud pip before the weld can be inialised. The soer
spring however, does not have sucient 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
iniated the li coil briey lis 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 iniated 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 beer
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 alternave front end cap assemblies and chucks are available
for welding dierent sizes of stud and to assist with producon xtures and
templates. These can be found in the ACCESSORIES secon 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 installaon may present potenal risks and dangers. Please 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.
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
Installaon must be according to the seng up procedure detailed in the appropriate
operang/installaon guides for the equipment being used 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 DANGER 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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SAFETY
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. 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 documentaon. 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 oer, at an addional cost, personnel training packages, should a
cercate of competency be required for operang/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 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.).
7. 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
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
direcve, Taylor Studwelding Systems Ltd oers 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 entled
"Capacitor Discharge Stock list" which can found by scanning
the QR code below or alternavely 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
adjusng the backstop screw as shown.
Securely ghten the chuck backstop locking nut to
maintain the required protrusion.
Aer seng the chuck, insert it
into the pistol chuck holder and
push rmly home unl it comes to
a rest.
Tighten the chuck locking nut with
the box spanner provided. Hand
ghtis 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 seng method diers dependent on the type of pistol being
used:
SETTING THE C2 TYPE PISTOL
Set the pistol spring pre-load to the
appropriate seng for the stud/
material to be welded. This is
achieved by twisng the rear end
cap adjuster.
The indicator window on the side of
the pistol indicates the seng.
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 adjusng the li to the
maximum posion. This is achieved
by turning the rear end cap adjuster
in an an-clockwise direcon unl
it reaches its end of travel.
Once this is done, you will need to
nd the Zero Li Posion.

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SETTING UP & WELDING
To do this place the pistol into the
welding posion, pressing down on
the pistol unl 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
posion. Again turn the rear end
cap adjuster, this me clockwise.
Connue to turn the adjuster unl
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 posion.
The required li can now be set.
This is achieved by once more
turning the rear end cap adjuster in
an an-clockwise direcon. 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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SETTING UP & WELDING
Set up an appropriate controller for
use with your pistol and connect and
install it in line with its operang
instrucons.
The Taylor Studwelding Systems
pistols outlined in this operang
guide are designed to operate across
a range of CD controllers, including
but not exclusive to those
manufactured by Taylor
Studwelding Systems Ltd.
The type C2 pistol is a contact pistol
and will work with most controllers
given an appropriate connecon
prole whilst the type LG2 pistol is
a li gap pistol and must be paired
with a suitable li gap controller.
Having selected, connected and set
up your controller, pistol, work
piece etc. It is now me to weld.

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SETTING UP & WELDING
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.
The welding process
is :-
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.
INITIAL PRESSURE LIFT & RELEASE STRIKE ARC FUSION & IMMER-
SION
COMPLETED WELD
LIFT GAP PROCESS, TIME
TAKEN (s) - LG2 0.000 0.0005 0.001 0.0015 0.002
CONTACT PROCESS, TIME
TAKEN (s) - C2 0.000  0.001 0.002 0.003

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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 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 ASSESSMENT/TESTING
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 :
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
the BS EN ISO 14555:2014 specicaon .
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.

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METHODS OF STUD LOCATION
Economic stud locaon 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 producon and one o components. The
spacing of the tripod legs allow for ease of stud placement onto a scribed or
pencilled mark. Centre punch indentaons must not be used (see note below).
NOSE CONE ASSEMBLY.
This is generally used for high volume and repeve work, or where a greater level
of accuracy is required. Simple jigs made from Tufnol (a thermo-seng plasc) or
sheet metal can easily be made, allowing for speedy and accurate producon.
Advice on jig manufacture can be obtained from your sales representave.
EXTENDED LEG ASSEMBLY.
This is used where a requirement for welding very long studs is necessary. The
extended leg assembly allows studs up to 200 mm long to be welded.
IMPORTANT NOTE !
Manual centre punch indentaons must NOT be used for stud locaon
as this will have the same eect as shortening the pip on the weld stud
and could adversely aect the weld quality.
If praccal consideraons compel the use of indentaons, then we would suggest
the use of either an automac centre punch or a punch press set only to produce
the shallowest of indents consistent with the ease of stud locaon.
The seng chart parameters may have to be altered to achieve the opmum
condions detailed in the seng up and welding procedure.
If in any doubt, please seek the advice of your local technical representave.

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COMPONENT EXPLOSION AND PARTS LISTING
ITEM QTY PART No. DESCRIPTION
1171-101-030 CONTROL PLUG
23.5 71-300-010 CONTROL CABLE (per metre)
3181-101-051 WELD PLUG
4371-300-002 WELD CABLE (per metre)
5671-101-032 CABLE CLIP (NOT SHOWN)
16
2
1
4
3
PISTOL TYPE
C2

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COMPONENT EXPLOSION AND PARTS LISTING
ITEM QTY PART No. DESCRIPTION
1379-101-052 TRIPOD LEG
2179-101-051 FRONT END CAP
32Z115-05-006 SCREW
4171-101-002 CHUCK NUT
5171-101-004 BELLOWS RETAINING RING
6171-101-202 BODY RING
7171-101-203 REAR END CAP
84Z120-04-020 SCREW
9171-101-003 BELLOWS
17
78
56
34
12
9
SEE PAGES XX FOR CHUCKS
AND ACCESSORIES.

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COMPONENT EXPLOSION AND PARTS LISTING
ITEM QTY PART No. DESCRIPTION
1171-101-200 PISTOL BODY MOULDING PAIR
2171-101-217 DECAL STICKER
32Z250-10-019 SCREW
18
1
2
3
PISTOL SCHEMATIC
X1
RED or BLUE 24 PIN
TRIGGER SWITCH CONTROL
BLUE or RED 3PLUG
X4

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COMPONENT EXPLOSION AND PARTS LISTING
ITEM QTY PART No. DESCRIPTION
1171-101-220 FLEXI-BRAID ASSEMBLY
23Z600-05-000 WASHER
31Z115-05-012 SCREW
41Z200-04-006 SCREW
51Z700-05-022 TERMINAL
62Z115-05-008 SCREW
7171-101-201 TERMINAL PLATE
8181-101-279 PUSHBUTTON SWITCH
92Z225-08-914 SCREW
10 2Z605-05-999 WASHER
11 171-101-214 CABLE CLIP
12 171-101-033 CABLE SLEEVE
13 3Z615-05-000 WASHER
14 171-101-034 CABLE SLEEVE
19
1
2
3
4
56
7
8
9
SEE NEXT PAGE FOR 10
SHAFT BREAKDOWN
11
12 13 14

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COMPONENT EXPLOSION AND PARTS LISTING
ITEM QTY PART No. DESCRIPTION
1171-101-215 BEARING
2171-101-204 BEARING HOUSING
3171-101-205 SHAFT
4171-101-014 SPRING
5271-101-213 DETENT
6171-101-207 ADJUSTER DRIVER
72Z800-04-026 BHAR PIN
82Z800-06-028 SAR PIN
9171-101-206 PRE-LOAD ADJUSTER
10 1Z505-04-000 NUT
11 1Z400-04-016 SCREW
20
56
34
12
10 11
89
7