Taylor CD-MULTIGUN User manual

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TAYLOR STUDWELDING
SYSTEMS LIMITED.
OPERATING GUIDE
FOR
CD-MULTIGUN
COMPACT CAPACITOR DISCHARGE
STUDWELDING EQUIPMENT
A TAYLORMADE CAPACITOR DISCHARGE PRODUCT
VISIT OUR WEBSITE

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INDEX
PAGE CONTENT
3GENERAL INFORMATION
5INTRODUCTION
6EQUIPMENT SCHEDULE
7EXTERIOR FEATURES
9SAFETY
12 SETTING UP AND WELDING
17 WELD SETTINGS
20 LOCATION METHODS
21 WELD ASSESSMENT / TESTING
22 CONTROLLER EXPLOSION AND PARTS LIST
28 CIRCUIT SCHEMATIC
29 EC 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 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 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 MULTIGUN CONTROLLER 99-100-194
ACCESSORIES ( NOT SUPPLIED WITH EQUIPMENT)
No. OFF DESCRIPTION PART No.
1-3CHUCK KEY 79-101-111
1-3CD CONTACT PISTOL 99-100-020
or CD LIFT GAP PISTOL 99-100-023
NOTE! LIFT GAP PISTOLS MUST BE USING A 2 WIRE TRIGGER
WHICH WOULD REQUIRE ALL 4 PINS IN THE CONTROL
PLUG TO BE CONNECTED.
DO NOT USE OLDER 1 WIRE TRIGGER PISTOLS (WHERE PIN
2 IS UN-CONNECTED) AS THIS WILL DAMAGE THE PCB IN
THE CONTROLLER, CAUSING IT TO FAIL.
1EARTH CABLE ASSEMBLY 99-100-125
See pages 34 to 40 of this manual for a selecon of accessories available from
either your local stockist or the manufacturer.

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EXTERIOR FEATURES
FRONT PANEL
VOLTAGE DISPLAY SETTING BUTTON MAINS FUSE
INDICATOR LED’sON/OFF
SWITCH
PISTOL
CONNECTION
PANEL
MODE DISPLAY
EARTH
CONNECTION
ADJUSTER KNOB PANEL
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
capacitors to the pre-selected voltage.
RESET (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.

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EXTERIOR FEATURES
REAR PANEL
ON / OFF SWITCH
SERIAL/DATA PLATE
COOLING FAN
MAINS INPUT LEAD
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 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
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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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
posion. Ensure that this is done in line with the
notes and safety recommendaons on pages 9
through 11 of this manual.
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.
At switch ON the controller
will briey charge to 35V on
the VOLTAGE display and the
MODE display will read
“TAYLOR STUD CD
MULTIGUN”
Within 5 seconds the MODE display will change
to “Welding Mode” and the VOLTAGE display
will change to match the voltage shown in the
MODE display. This is the lowest voltage that has been
previously set for one of the pistols. The controller can
operate up to three pistols independently. It does this
by inially charging the capacitors to the lowest of the
three pre-seable voltages and holding there.
PRE-SETTING THE VOLTAGES
Press and release the “SET” buon once.
The MODE display will change to read “Sengs
Mode Voltage 1 = XX” (where XX = the last
voltage set in the memory). Turn the ADJUST
knob to change the value of XX to the required
seng (see the tables on pages 18 - 20 for
suggested sengs).
Repeat these two steps to set Voltages 2 & 3. Aer seng Voltage 3, press and
release the “SET” buon one more me. The MODE display will return to
“Welding Mode Voltage = XX” (XX will now be the lowest number of the three
voltages that have been pre-set above) and the VOLTAGE display will also show
this value.
If you are using less that three pistols, it is a good idea to set the voltages of
the unused pistol(s) to a value higher than the pistol(s) in use. This will ensure
that the hold voltage at start-up is instantly available

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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.
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.

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SETTING UP & WELDING
SETTING UP & WELDING
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 13918.
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 (18 to 20) detail the suggested sengs for the Mulgun
controller, 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 manufac-
tured 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
CONTACT 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

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WELD SETTINGS
CONTACT 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

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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 compo-
nents. 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.
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 ac-
curate 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.