Taylor DA1-A, DA2-A, DA3-A Operating Manual
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OPERATING GUIDE
FOR
TYPES DA1-A,
DA2-A & DA3-A
DRAWN ARC PISTOLS
TAYLOR STUDWELDING
SYSTEMS LIMITED
A TAYLORMADE DRAWN ARC STUD WELDING PISTOL
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INDEX
PAGE No. CONTENT
3 USEFUL INFORMATION.
5 IMPORTANT SAFETY INFORMATION.
7 INTRODUCTION TO STUDWELDING.
8 SETTING UP AND WELDING.
12 EXPLODED DIAGRAMS AND PARTS LISTINGS.
17 ACCESSORIES - STANDARD FOOT ASSEMBLIES.
19 ACCESSORIES - GAS FOOT ASSEMBLY.
20 ACCESSORIES - CHUCKS - EUROPEAN SCREW-ON TYPE.
21 ACCESSORIES - CHUCKS - EUROPEAN SCREW-ON GAS TYPE
UK TAPER FIT - ADJUSTABLE
22 ACCESSORIES - FERRULE GRIPS
BENDING BAR
23 EC DECLARATION OF CONFORMITY.
2
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USEFUL INFORMATION
3
MANUFACTURERS DETAILS
TAYLOR STUDWELDING SYSTEMS LIMITED
COMMERCIAL ROAD
DEWSBURY
WEST YORKSHIRE
WF13 2BD
ENGLAND
TELEPHONE : +44 (0)1924 452123
FACSIMILE : +44 (0)1924 430059
email : sales@taylor-studwelding.com
WEB : www.taylor-studwelding.com
SALES DIRECT TEL : +44 (0)1924 487703
TECHNICAL HELPLINE : +44 (0)1924 487701
You may wish to record the details of your controller below as this informaon will help
with any technical assistance you may require:
PURPOSE AND CONTENT OF THIS GUIDE
This guide has been wrien for :
• The personnel of the end-user responsible for the installaon and maintenance of the
pistol.
• The operator of the welding pistol.
This guide contains informaon relang to :
• Installaon and connecon.
• Operaon.
• Technical specicaons and parameters.
• Spare parts.
PISTOL SERIAL No.
DATE PURCHASED.
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USEFUL INFORMATION
4
FURTHER INFORMATION
Should you require addional technical informaon, 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 informaon which is a pre-requisite for safe Operaon
of the pistol. The operang 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 pistol 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
PISTOL.
PLEASE OBSERVE CAREFULLY ALL SAFETY PROCEDURES/INSTRUCTIONS.
DUE TO THE POWER REQUIREMENTS AND ELECTROMAGNETIC EMISSIONS
PRODUCED DURING NORMAL USE, THIS PISTOL MUST ONLY BE OPERATED IN
AN INDUSTRIAL ENVIRONMENT.
NEVER REMOVE ANY PORTION OF THE UNIT HOUSING WITHOUT FIRST
ISOLATING THE PISTOL FROM THE CONTROLLER.
Taylor Studwelding Systems Limited reserves the right to amend the contents of this guide without nocaon.
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IMPORTANT SAFETY INFORMATION !
5
PROTECT YOURSELF AND OTHERS !
Read and understand these safety notes.
1. ELECTRICAL
No poron of the outer cover of the welding pistol should be removed by anyone other
than suitably qualied personnel and never whilst mains power is connected.
ALWAYS DISCONNECT THE MAINS LEAD BEFORE ATTEMPTING ANY
MAINTENANCE.
BEWARE - RISK OF ELECTRIC SHOCK !
Do not use any uids to clean electrical components as these may penetrate into the
electrical system.
Installaon must be according to the seng up procedure detailed on page 8 of this guide
and must be in line with naonal, regional and local safety codes.
2. FIRE
During welding small parcles of very hot metal are expelled. Ensure that no combusble
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 protecon.
Fumes and gases can seriously harm your health. Use the equipment only in a suitably
venlated area. If venlaon is inadequate, then appropriate fume extracon equipment
must be used.
Hot metal spaer can cause re and burns. Appropriate clothing must be worn. Clothing
made from, or soiled with, combusble materials must NOT be worn.
Have a re exnguisher nearby and know how to use it.
Magnec elds from high currents can aect heart pacemakers or other electronically
controlled medical devices. It is imperave that all personnel likely to come into the vicinity
of any welding plant are warned of the possible risks before entering the area.
4. MAINTENANCE
All cables must be inspected regularly to ensure that no danger exists from worn or
damaged insulaon or from unsound electrical connecons. 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.
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IMPORTANT SAFETY INFORMATION !
6
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 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.
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 operaon.
Do not hang connecng cables over sharp edges and do not install connecng cables near
heat sources or via trac routes where people may trip over them or they may be
damaged by the passage of vehicles (forklis etc).
7. INTERFERENCE
During welding operaons, intense magnec and electrical elds are unavoidably produced
which may interfere with other sensive Electronic equipment.
All Taylor Studwelding equipment is designed, manufactured and tested to conform the
current appropriate European standards and direcves regarding electromagnec
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. None of the components used in
the manufacture are toxic, carcinogenic or harmful to health in their “as supplied”
condion.
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INTRODUCTION TO STUDWELDING
7
The Taylor Studwelding DA2-A studwelding pistol when matched with an appropriate
controller and earth cables is intended for precision stud welding up to 20 mm diameter full
base studs. The pistol is lightweight, ergonomic and has been designed to operate with a
minimum amount of maintenance.
The energy required to carry out the welding operaon is derived from an appropriate
studwelding controller.
Taylor Studwelding Systems Ltd controllers are modern, robustly designed and oer
maximum reliability combined with an easy to understand operator interface.
THE PROCESS
The process of drawn arc studwelding is long established and well proven. The basic steps
are as follows :
• A measured amount of weld stud protrusion is set at the welding pistol.
• Once in posion, the pistol lis the stud away from the work-piece, simultaneously
striking an arc between the two.
• Both the p of the weld stud and the surface of the work-piece melt as the arc is
sustained for a pre-determined interval.
• At the compleon of the pre-determined interval, the pistol returns the weld stud to
the molten pool on the work-piece, thus forming a weld.
The most common and tradional drawn arc welds have a weld duraon greater than
100ms and employ the use of a single use ceramic arc shield, commonly referred to as a
ferrule. This ferrule helps to protect the arc during the weld and assists in formaon of the
nal llet. Post welding the ferrule is removed and disposed of.
It is possible to stud weld without a ferrule. When using this method it is recommended
pracce to employ a suitable shielding gas to reduce the amount of porosity in the
completed weld and improve weld quality.
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