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Taylor 800DA Operating Manual
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Taylor 800DA Operating Manual

Taylor 800DA Operating Manual

Drawn arc controller
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TAYLOR STUDWELDING
SYSTEMS LIMITED
OPERATING GUIDE
FOR
TYPE 800DA
DRAWN ARC CONTROLLER
V-21A

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Summary of Contents for Taylor 800DA

  • Page 1 TAYLOR STUDWELDING SYSTEMS LIMITED OPERATING GUIDE TYPE 800DA DRAWN ARC CONTROLLER V-21A...
  • Page 2 INDEX PAGE No. CONTENT USEFUL INFORMATION. IMPORTANT SAFETY INFORMATION. INTRODUCTION TO STUDWELDING. GUIDE TO EXTERNAL FEATURES. SETTING UP AND WELDING. WELDING TIME AND CURRENT SETTINGS. VISUAL WELD INSPECTION. WELD TESTING. STUDWELDING TECHNIQUES. PARTS LIST & EXPLODED DIAGRAMS. CIRCUIT SCHEMATIC - WIRING. CIRCUIT SCHEMATIC - DISPLAY PCB.

  • Page 3: Useful Information

    USEFUL INFORMATION 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 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 information will help with any technical assistance you may require: CONTROLLER SERIAL No.
  • Page 4 DO NOT USE THIS WELDING POWER SOURCE FOR PIPE THAWING. THIS EQUIPMENT HAS BEEN EMC TESTED AND APPROVED IN ACORDANCE WITH BS EN 60974-10 (CATEGORY 2). Taylor Studwelding Systems Limited reserves the right to amend the contents of this guide without notification. V-21A...

  • Page 5: Important Safety Information

    IMPORTANT SAFETY INFORMATION ! PROTECT YOURSELF AND OTHERS ! Read and understand these safety notes. 1. ELECTRICAL No portion of the outer cover of the welding controller should be removed by anyone other than suitably qualified personnel and never whilst mains power is connected. ALWAYS DISCONNECT THE MAINS LEAD BEFORE ATTEMPTING ANY MAINTENANCE.
  • Page 6 During welding operations, intense magnetic and electrical fields are unavoidably produced which may interfere with other sensitive Electronic equipment. All Taylor Studwelding equipment is designed, manufactured and tested to conform the current appropriate European standards and directives regarding electromagnetic emissions and immunity and as such is safe to use in any normal environment.
  • Page 7 INTRODUCTION TO STUDWELDING The Taylor Studwelding 800DA Drawn Arc controller when matched with an appropriate pistol and earth cables is intended for precision stud welding up to 12 mm diameter reduced base studs. The controller is easily transportable and has been designed to operate with a minimum amount of maintenance.
  • Page 8 GUIDE TO EXTERNAL FEATURES FRONT PANEL CARRYING HANDLE MAINS ON/OFF SWITCH VENTILLATION HOLES ! DO NOT OBSTRUCT ! WELDING EARTH CONNECTION SOCKET CONTROL PANEL SEE PAGE 9 SHIELDING GAS OUTLET SOCKET PISTOL CONTROL CONNECTION SOCKET PISTOL WELDING CONNECTION SOCKET V-21A...
  • Page 9 GUIDE TO EXTERNAL FEATURES CONTROL PANEL WELDING TIME SETTING PUSHBUTTON WELDING INDICATOR - GREEN WELDING TIME/GAS PURGE TIME DISPLAY WINDOW PISTOL TRIGGER ACTUATED INDICATOR - YELLOW ADJUSTER KNOB GAS PURGE TIME SETTING PUSHBUTTON GAS FLOWING INDICATOR - GREEN STUD TO WORKPIECE CONTACT INDICATOR - YELLOW PISTOL LIFT COIL ENERGISED INDICATOR - YELLOW 10.
  • Page 10 GUIDE TO EXTERNAL FEATURES BACK PANEL RATING/SERIAL PLATE SHIELDING GAS INLET 3 Ph MAINS CABLE INLET GLAND VENTILLATION GRILLE ! DO NOT OBSTRUCT ! V-21A...
  • Page 11 SETTING UP AND WELDING Set up the control unit at the place of work, ensuring that the mains switch is in the OFF position. Plug the controller into a suitable three phase AC supply with a 32A motor rated fuse/breaker. Plug the welding earth cables into the controller.
  • Page 12 A guide to the recommended time settings can be found on page 14 of this guide. The 800DA controller has a fixed 800A current output, with only welding time being operator adjustable. Referring back to the control panel guide on page 9, set...
  • Page 13 SETTING UP AND WELDING Place the pistol perpendicular to the work piece with the stud touching down at the desired location to be welded. Press down on the pistol until the ceramic ferrule rests firmly on the work piece. Press the trigger to initiate the weld sequence.
  • Page 14 The setting charts were established with the performance of repetitive weld tests using the 800DA controller and our standard DA7-A pistol with SC studs manufactured to standard BS EN ISO 13918 and mild steel grade CR4 and were performed using a shielding gas purge (Argoshield Light) at 5l/min.
  • Page 15 VISUAL WELD INSPECTION This page will help you to recognise a poor weld when you see one and give some of the possible explanations as to how it may have occurred. Your test welds should look like the first example diagram in the series and once you transfer to the actual job, periodic checks should be made to ensure that your welding is consistently good.
  • Page 16 WELD TESTING There are two factors which should receive special attention in establishing visually whether or not a stud weld is sound. These are : • The length after weld (L.A.W.) of the stud should be correct. That is to say that a stud which is intended to be 50 mm long after welding, should be correct within +0/-1 mm.
  • Page 17 WELD TESTING 2. NON DESTRUCTIVE TESTING. Generally the most practical way of testing threaded stud welds, without destroying the stud, is with the use of proof tests. A torque wrench is particularly useful for this purpose. Below and overleaf are some tables which you may find useful. However, it must be noted that : •...
  • Page 18 WELD TESTING Stud loads - Full Base Drawn Arc Studs (kN) Mild Steel Mild Steel Mild Steel Stainless Stainless Stainless Steel Steel Steel Thread Yield Safe Yield Safe M5 x 0.8 M6 x 1.0 10.6 M8 x 1.25 15.2 12.3 19.6 12.7 10.1...
  • Page 19 STUDWELDING TECHNIQUES The operating instructions given previously in this guide apply to the majority of general applications where it is possible to use the pistol in the down hand position and with standard cable lengths. For many applications these conditions do not apply and the following notes will give some guidance as to the methods used to obtain satisfactory results for a variety of applications.
  • Page 20 STUDWELDING TECHNIQUES 5. WELDING STUDS LESS THAN 25 mm LONG USING FERRULES. As we have seen previously, the stud is held in a recess in the chuck and must be long enough to allow us to set the correct protrusion. A standard chuck has a recess 12 mm deep and ferrules vary in length up to 13.5 mm high.
  • Page 21 STUDWELDING TECHNIQUES 9. WELDING CLOSE TO CORNERS, FLANGES AND OTHER OBSTACLES. When welding close to the edge of a plate, in / on a corner, on long strips of narrow plate etc. An effect known as "arc-blow" occasionally will produce an uneven fillet, in such a fillet, most of the material is blown to one side of the stud.

  • Page 22: Parts List & Exploded Diagram

    PARTS LIST & EXPLODED DIAGRAM SEE PAGE 23 FOR BREAKDOWN OF CONTROLLER ITEM No. OFF PART No. DESCRIPTION 81-113-013 COVER STICKER 81-113-004 HOUSING COVER 81-120-032 CARRYING HANDLE V-21A...
  • Page 23 PARTS LIST & EXPLODED DIAGRAM SEE PAGES 24 & 25 FOR SEE PAGE 27 A BREAKDOWN OF THE FOR BREAKDOWN FRONT PANEL OF CONTROL DECK SEE PAGE 28 FOR BREAKDOWN OF BACK PANEL SEE PAGE 26 FOR BREAKDOWN OF TRANSFORMER CRADLE ITEM No.
  • Page 24 PARTS LIST & EXPLODED DIAGRAM ITEM No. OFF PART No. DESCRIPTION 81-113-010 PUSHBUTTON 81-113-009 PANEL OVERLAY 81-113-007 HOUSING FRONT PANEL 81-113-020 PILOT ARC RESISTOR 81-113-015 HANDLE BRACKET 70-102-025 CONTROL SOCKET 81-106-031 WELD SOCKET PFX-CSS-B06-BUL GAS SOCKET 81-108-067 ON/OFF SWITCH 81-113-025 FILTER CAPACITOR V-21A...
  • Page 25 PARTS LIST & EXPLODED DIAGRAM ITEM No. OFF PART No. DESCRIPTION 81-104-030 CONTROL KNOB 81-104-032 KNOB CAP 81-113-026 70-102-047 THYRISTOR CLAMP 70-102-046 THYRISTOR 81-113-019 THYRISTOR MOUNTING PLATE 70-106-044 THYRISTOR CLAMP PLATE 81-113-017 EARTH SOCKET LINK BAR 81-113-002 WELDING RECTIFIER 81-113-018 PISTOL SOCKET LINK BAR V-21A...
  • Page 26 PARTS LIST & EXPLODED DIAGRAM ITEM No. OFF PART No. DESCRIPTION 81-113-001 WELDING TRANSFORMER Z450-06-165 M6 x 165 STUD 81-113-008 TRANSFORMER CRADLE 81-113-023 WIRING HARNESS COMPLETE (NOT ILLUSTRATED) V-21A...
  • Page 27 PARTS LIST & EXPLODED DIAGRAM ITEM No. OFF PART No. DESCRIPTION 81-120-120 FUSEHOLDER 81-106-051 DIN RAIL 70-105-190 EARTH BLOCK 98-103-052 HAZARD WARNING LABEL 81-106-262 EARTH LABEL 81-113-029 VARISTOR 81-113-028 SOLID STATE RELAY 81-113-027 HEATSINK 81-106-044 TERMINAL 81-106-116 TERMINAL END COVER 81-113-016 FILTER 81-113-032...
  • Page 28 PARTS LIST & EXPLODED DIAGRAM ITEM No. OFF PART No. DESCRIPTION 81-113-015 HANDLE BRACKET 81-113-005 BACK PANEL 81-108-019 CABLE GLAND 81-106-174 SERIAL LABEL PFX-CSS-B06-BUL GAS INLET SOCKET 70-102-010 70-102-018 FAN FINGER GUARD 71-300-008 MAINS FLEXIBLE CABLE /m (NOT ILLUSTRATED) 81-108-073 MAINS 32A 5 PIN PLUG (NOT ILLUSTRATED) V-21A...
  • Page 29 CIRCUIT SCHEMATIC - WIRING V-21A...
  • Page 30 CIRCUIT SCHEMATIC - PCB V-21A...
  • Page 31 ACCESSORIES A pair of earth cables must be connected to the controller in this user guide. A pair of ca- bles comprises 2 off the standard cable assembly part number listed below. STANDARD EARTH CABLE ASSEMBLY FOR SYSTEM 800 99-101-046 Spare parts for the maintenance of earth cables are listed below: WELD PLUG 81-101-051...

  • Page 32: Eu Declaration Of Conformity

    EU DECLARATION OF CONFORMITY Responsible Party Name Taylor Studwelding Systems Ltd Address Commercial Road Dewsbury West Yorkshire WF13 2BD Designation of Product : Studwelding equipment 800DA Studwelding gun series DA2-A to DA20 The above mentioned equipment complies with the requirements of the following directives :...