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Summary of Contents for Taylor 2000E
- Page 1 TAYLOR STUDWELDING SYSTEMS LIMITED OPERATING GUIDE FOR TYPE 2000E & TYPE 2700E DRAWN ARC CONTROLLERS V‐2A ...
- Page 2 INDEX PAGE No. CONTENT 3 USEFUL INFORMATION. 5 IMPORTANT SAFETY INFORMATION. 7 INTRODUCTION TO STUDWELDING. 8 GUIDE TO EXTERNAL FEATURES. 11 SETTING UP AND WELDING. 14 WELDING TIME AND CURRENT SETTINGS. 15 VISUAL WELD INSPECTION. 16 WELD TESTING. 19 STUDWELDING TECHNIQUES. 22 PARTS LIST & EXPLODED DIAGRAMS. 26 PCB’s ‐ LED GUIDE. 28 CIRCUIT SCHEMATIC S. 34 ACCESSORIES. 35 EC DECLARATION OF CONFORMITY. 2 V‐2A ...
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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 WEB : www.taylor‐studwelding.com ... -
Page 4: Further Information
If the equipment 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 CONTROLLER. PLEASE OBSERVE CAREFULLY ALL SAFETY PROCEDURES/INSTRUCTIONS. DUE TO THE POWER REQUIREMENTS AND ELECTROMAGNETIC EMISSIONS PRODUCED DURING NORMAL USE, THIS MACHINE MUST ONLY BE OPERATED IN AN INDUSTRIAL ENVIRONMENT. THIS MACHINE OPERATES FROM A MAINS SUPPLY OF 380/415V AC @ 50/60 Hz NEVER REMOVE ANY PORTION OF THE UNIT HOUSING WITHOUT FIRST ISOLATING THE CONTROLLER FROM THE MAINS ELECTRICAL SUPPLY. NEVER OBSTRUCT THE UNDERSIDE, FRONT OR REAR PANELS AS THIS MAY CAUSE THE UNIT TO OVERHEAT DURING OPERATION. Taylor Studwelding Systems Limited reserves the right to amend the contents of this guide without notification. 4 V‐2A ... -
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. BEWARE ‐ RISK OF ELECTRIC SHOCK ! Do not use any fluids to clean electrical components as these may penetrate into the electrical system. ... -
Page 6: Installation
IMPORTANT SAFETY INFORMATION ! 5. 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 times. 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 operation. Do not hang connecting cables over sharp edges and do not install connecting cables near heat sources or via traffic routes where people may trip over them or they may be damaged by the passage of vehicles (forklifts etc). 7. INTERFERENCE During welding operations, intense magnetic and electrical fields are unavoidably produced and these 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. 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” condition. 6 V‐2A ... -
Page 7: Introduction To Studwelding
INTRODUCTION TO STUDWELDING The Taylor Studwelding 1600E Drawn Arc controller when matched with an appropriate pistol and earth cables is intended for precision stud welding up to 20 mm diameter full base studs. The controller is easily transportable and has been designed to operate with a minimum amount of maintenance. The energy required to carry out the welding operation is derived from a fully micro‐ processor controlled transformer‐rectifier inside the controller. Taylor Studwelding Systems Ltd pistols are modern, ergonomically designed and offer maximum comfort in handling with minimum operator fatigue. 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 position, the pistol lifts the stud away from the work‐piece, simultaneously striking an arc between the two. Both the tip of the weld stud and the surface of the work‐piece melt as the arc is sustained for a pre‐determined interval. At the completion 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 traditional drawn arc welds have a weld duration 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 formation of the final fillet. Post welding the ferrule is removed and disposed of. It is possible to stud weld without a ferrule. This method is more commonly employed with welds having a duration of less than 100 ms and this type of weld is referred to as short ... - Page 8 GUIDE TO EXTERNAL FEATURES 1 2 3 7 4 8 5 9 6 FRONT PANEL 1. GUIDING HANDLES ! NOT FOR LIFTING ! 2. MAINS ON/OFF SWITCH 3. CONTROL PANEL ...
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Page 9: Control Panel
GUIDE TO EXTERNAL FEATURES 1 2 3 4 5 6 7 8 ... - Page 10 GUIDE TO EXTERNAL FEATURES 1 2 3 5 6 4 BACK PANEL 1. LIFTING EYEBOLT 2. VENTILLATION LOUVRES ! DO NOT OBSTRUCT ! 3. RATING/SERIAL PLATE 4. SHIELDING GAS INLET SOCKET 5. 3 Ph MAINS CABLE INLET GLAND ...
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Page 11: Setting Up And Welding
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 100A motor rated fuse/breaker. Plug the welding earth cables into the controller. Note that the cable end weld plug has a peg which mates with the key slot in the panel mounted socket. IMPORTANT! Secure the connectors with a clockwise turn until they lock. Failure to do this may result in damage to the connectors during welding. Attach the welding earth clamps to the work piece at approximately 180° to each other; this will help prevent "arc‐ blow" when welding takes place. Prior to fitting 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 connection. Plug the welding pistol cable into the controller. Note that the cable end weld plug has a peg which mates with the key slot in the panel mounted socket. IMPORTANT! Secure the connectors with a clockwise turn until they lock. Failure to do this may result in damage to the connectors during welding. Plug the pistol control cable into the controller. Note that the cable end plug and panel‐mounting socket are keyed to prevent incorrect fitting. Push the plug firmly home and twist the locking ... - Page 12 SETTING UP AND WELDING Switch the controller ON by turning the mains switch clockwise through 90°. The ventilation fan will start and the display will illuminate and carry out a start up diagnostic routine taking approx’ 6 seconds. A guide to the recommended time and current settings can be found on page 14 of this guide. Referring back to the control panel guide on page 9, set the controller by following these simple steps :‐ SETTING WELD CURRENT 1. Press and hold the current setting pushbutton (1). 2. Turn the adjuster knob (6) until the required current is displayed in the welding current display window (3). 3. Release the pushbutton (1). The current is now set. NOTE! If the pushbutton (1) is held for more than 3 seconds before turning the adjuster knob (6), the display (3) will change to last weld current readback mode and will need to be released and re‐pressed. SETTING WELD TIME 1. Press and hold the welding time setting pushbutton (7). 2. Turn the adjuster knob (6) until the required time is displayed in the time display window (2). 3. Release the pushbutton (7). The welding time is now set. NOTE! If the pushbutton (7) is held for more than 3 seconds before turning the adjuster knob (6), the display (2) will change to last system error code display mode and will need to be released and re‐pressed. SETTING THE GAS PURGE TIME ...
- 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. See the section on Studwelding Techniques for further advice. The welding process is as follows: ‐ 1. Start. 2. Pistol lifts stud. 3. Pilot Arc strikes. 4. Main Arc strikes melting both stud and workpiece. 5. Arc stops. Pistol plunges stud into molten pool. 6. Weld complete. Having welded the stud, draw the pistol vertically off the stud. Failure to do this may cause the split tines of the chuck to splay out. This will result in the chuck and stud arcing together during subsequent welds. Finally, remove the ferrule by lightly tapping until it shatters. Visually inspect the weld. For a guide to the inspection of the welded stud see the sections on Inspecting and Testing Welded Studs. ...
- Page 14 WELDING TIME AND CURRENT SETTINGS STUD TYPE ACTUAL WELD WELD This page is intended as a guide to setting your DIAMETER CURRENT TIME machine. (mm) (A) (ms) 5FB 5 400 100 6RB 4.7 376 94 A set of basic formulae as defined by the British 6FB 6 480 120 Standard BS EN ISO 14555:2006 (European Standard EN 8RB 6.2 496 124 ISO 14555:2006) Annex A.2.7.2.2 and Annex A.2.7.2.4 8FB 8 640 160 may be used to calculate the current and time settings 10RB 7.9 632 ...
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Page 15: Visual Weld Inspection
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. POINTS TO LOOK FOR IRRESPECTIVE OF PROCESS USED. L.A.W. (Length After Welding). This should be correct to within + 0 / ‐ 1 mm. The base fillet of the welded stud is complete. The welded stud is perpendicular to the work‐piece. WHEN USING A CERAMIC FERRULE. This diagram is an example of a good normal weld, fulfilling the criteria above i.e. The LAW is correct, the stud has a complete, well formed and even fillet and is also perpendicular to the work‐piece. The following examples will help you to recognise the most common types of poor weld, explain the possible causes of these problems and how to remedy them. EXAMPLE 1 PROBLEM : Insufficient heat, causing the L.A.W. to be too long and the fillet to be underdeveloped and/or incomplete. REMEDY : Increase the welding time (see page 12). EXAMPLE 2 PROBLEM : Excessive heat, causing the L.A.W. to be too short and the fillet to be too large and messy, spreading out under the ferrule and/or ... - 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. A word of explanation is perhaps needed on this point. All studs produced include a "weld allowance". This allowance is so arranged for the different diameters of stud, that it will be completely melted during the welding process, provided of course that the correct conditions have been established and the correct values of current and time are used. The fillet of metal formed around the base of the stud should be well formed, reasonably evenly distributed, completely free from blow holes and of a silver blue colour. These two factors combined form the basis of all visual stud weld examination. It should be the aim of every operator to produce these results. Under normal conditions a stud welded to clean mild steel plate of adequate thickness having the correct L.A.W. and fillet formation. as described above, will be a satisfactory weld. It should be remembered, however, that different applications or conditions will produce slightly different visual results, particularly in the appearance of the fillet, i.e.. Slightly rusty, dirty or oily plate will produce blow holes in the fillet, in proportion to the degree of plate contamination. Welding close to some magnetic obstruction may produce uneven fillet distribution. Too much power will produce a fillet that flows too easily and is lost either up in the threads of the stud or out through the ferrule vents, while too little power may not melt sufficient material to form a complete fillet. It is important, therefore, to judge the degree to which these possible variations will affect the weld strength, but in general, provided that the L.A.W. is correct and the fillet formation is not unsightly, a visual examination is all that is required. Further testing may be carried out on a "percentage of production" basis, and the methods used fall into the classes outlined below. 1. DESTRUCTIVE TESTING. Should only be used on studs welded to samples and test pieces. Hammering a stud over may look spectacular, but it is not a satisfactory test, as the direction and force behind the blows is uncontrolled, as also is the point at which the ...
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Page 17: Non Destructive Testing
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 : Formulas & data shown are intended for guidance only. In applications where control of preload is important, the torque ‐ tension relationship should be determined experimentally on the actual parts involved including any lubricants. The coefficient of friction (k) varies with material, surface finish and lubricity of threads and bearing areas of fastened parts. For standard steel screws it is 0.19 to 0.25 and 0.13 to 0.17 for plated screws. Anti‐ seize materials and lubricants can lower k to 0.05. For some stainless steel threads and parts not coated or lubricated k may be as high as 0.33 All the figures are approximate and do not form part of any specification. Designers and specifiers must satisfy themselves that the studs and materials chosen are suitable for their particular application. All torque figures are calculated by the formula : T = kDP Where : T = Torque (Nm) D = Effective Stud Diameter (m) k = Coefficient of Friction (0.2 used for calculations) ... - Page 18 WELD TESTING Stud loads ‐ Full Base Drawn Arc Studs (kN) Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel Stainless Steel Thread UTS Yield Safe UTS Yield Safe M5 x 0.8 5.8 4.7 3.7 7.4 4.8 3.8 M6 x 1.0 8.2 6.6 5.3 10.6 6.8 5.4 M8 x 1.25 15.2 12.3 9.8 19.6 12.7 10.1 M10 x 1.5 23.8 19.2 15.4 ...
- 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. 1. WELDING TO A PLATE IN THE HORIZONTAL POSITION. In this position there is a tendency for the weld metal to run to the underside of the stud during welding, due to the action of gravity, resulting in an uneven fillet. The effect is more noticeable as stud diameter increases and generally speaking it is not recommended that studs of 12 mm diameter and over be welded to vertical plates for this reason. The essential requirement to obtain satisfactory fillet formation is to use the shortest weld time possible with increased weld current. Welding to a vertical surface reduces the maximum size of the stud a given power source will weld. It must be remembered, that greater care is required to ensure that the stud is perpendicular to the work piece. A special tripod foot attachment can be supplied if required. Take particular care to keep the ferrule grip, foot adapter and chuck clean. 2. WELDING TO A PLATE IN THE OVERHEAD POSITION. IMPORTANT ! You must protect your face and shoulders with a helmet and cape before carrying out overhead welding operations. Weld spatter can do a lot of damage ! Firstly, obtain satisfactory weld settings in the down hand position before making attempts in the overhead position. Since the weld metal is transferred from stud to plate in small particles in the down hand position, it follows that, when welding overhead, the transfer takes place against gravity. As with vertical welding the best results will be achieved using the shortest possible weld time with increased weld current. It is important that the ferrule grip, foot adapter and chuck are kept free from spatter build up as this can cause stud return problems or possibly short out/bridge out the weld. 3. PISTOL ADJUSTMENTS WHEN WELDING IN THE VERTICAL OR OVERHEAD POSITIONS. Problems may be encountered when welding in the vertical or overhead positions with a damped pistol. To prevent problems occurring, where it is possible to do so, the damping effect should be removed or turned off. Welding can then continue as outlined in sections 1. and 2. 19 V‐2A ...
- Page 20 STUDWELDING TECHNIQUES 4. USING LONG CABLE LENGTHS. Frequently the pistol must be used some distance from the nearest available mains supply, for instance on board ship, in power stations and building construction, in workshops building large pre‐fabricated structures etc. In these cases long lengths of welding cable are used and it must be realised at the outset that, the longer the cables the smaller the maximum diameter of stud which can be welded with a given power source. To help get over this problem, if larger diameter studs are to be welded with long lengths of cable, increase the welding cable conductor size. Try to avoid running the pistol cables and the earth cables alongside each other as this can cause a choking effect, reducing power. Also avoid coiling any excess cable as this will have the same effect. 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. Thus if a stud is much less than 25 mm LAW we shall not be able to obtain the correct protrusion, i.e.. The chuck may hit the ferrule on the return stroke and prevent the stud returning to the plate correctly. This problem may be overcome by using "shallow recess" chucks (the recess depth is only 6 mm) or if the studs are required to be very short, by using a special type of stud known as a "break‐off" type. These studs have an overall LAW of 30 mm and are welded using a standard chuck and ferrule. The stud is "grooved" at the required length from the welding end. After welding, the surplus portion of the stud is broken off with a pair of pliers. By these means, very short studs can easily be welded. 6. USING TEMPLATES TO ENSURE POSITIONAL ACCURACY. When welding studs around the periphery of a flange, i.e. for cover plates, inspection doors etc., positioning of the studs in relation to each other becomes most important. A simple template made from 2 mm sheet, shaped to suit the component and provided with clamps is usually the answer to this problem. The position of the studs is accurately marked and holes drilled in these positions to accept either the ferrule of the stud to be welded or, if using short cycle, the pistol gas shroud. The size of the holes should be the outside diameter of the ferrule / shroud +0.4 mm. It is also advisable to provide 2 mm thick pads underneath the template so that there is a space between the component and template, this space will allow the gases developed during welding to vent properly from the ferrule / shroud. For any further advice or help in the design of jigging or templates contact your local field sales engineer. 20 V‐2A ...
- Page 21 STUDWELDING TECHNIQUES 7. MINIMUM PLATE THICKNESSES WHEN STUD WELDING. When using standard Drawn Arc with ceramic ferrules, the minimum ratio of stud diameter to plate thickness is 4 : 1 for plate thickness greater than 3 mm and 3 : 1 for plate thickness between 1.5 mm and 3 mm. When using the short cycle system with or without gas purging it is possible to weld equivalent size studs onto slightly thinner sections, due to the short weld duration. These ratios ensure that the strength of the plate is sufficient to support a stud of a given size when it is loaded, without there being a tendency for the plate to distort. Occasionally, however, it may be necessary to weld a stud outside of these ratios. This can sometimes be accomplished without distortion by "heat sinking" the component, by using a flat copper or water cooled backing piece behind the weld area, to support the plate and assist in dissipating heat quickly. 8. WELDING STAINLESS STEEL. Austenitic stainless steel studs of the 18/8 g/N : weld decay proof type can be supplied for welding to similar parent material or mild steel. The technique does not differ from that used for mild steel stud welding. There is a tendency with larger diameters of stainless steel studs for metal transfer across the arc to take the form of large particles. If short circuits occur then the arc can be heard to splutter. This may occur with any diameter of stainless steel stud if the lift of the hand tool is not correct. Due to this tendency to transfer in large particles increased lift may be required and time settings should be kept as low as possible. 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. "Arc‐blow" is caused by the magnetic forces surrounding the arc being intensified in one direction, due to the presence of an air gap or the proximity of a large mass of magnetic material. It is dependant on a number of factors, size of stud, shape of component, position of earth connection, current density etc. No hard and fast rules can be applied to correct it. The following methods are generally helpful, but if satisfactory results cannot be obtained, our field staff will be pleased to advise you. Check that no other fault is present by welding a few studs on to a test piece and inspecting the fillet formation, before deciding that "arc‐blow" is causing the uneven fillet. "Arc‐blow" can sometimes be corrected by placing a block of steel near the position of the weld area, on the opposite side to that at which the fillet has blown. When welding near the edge of a plate, the fillet will be blown towards the general mass of material, i.e.. away from the edge. The block in this case should therefore be placed at the edge the plate, touching it, thus providing a more evenly distributed magnetic field. The earth ...
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Page 22: Parts List & Exploded Diagram
PARTS LIST PARTS LIST ITEM No. OFF PART No. DESCRIPTION 1 1 81‐120‐094 SIDE PANEL 2 1 81‐120‐011 TOP COVER 3 2 81‐120‐037 LIFTING EYEBOLT 4 1 81‐120‐093 SIDE PANEL 5 2 81‐120‐061 TAYLOR STUDWELDING STICKER 6 2 81‐120‐066 SYSTEM 2700 SIDE STICKER or 2 81‐120‐067 SYSTEM 2000 SIDE STICKER 22 V‐2A ... - Page 23 PARTS LIST & EXPLODED DIAGRAM 1 2,3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ...
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Page 24: Parts List
PARTS LIST 1 8 & EXPLODED 2 9 DIAGRAM 3 10 ... - Page 25 PARTS LIST & EXPLODED DIAGRAM 4 5 6 7 1 2 3 8 9 ...
- Page 26 PCB’s ‐ LED GUIDE (see page 9 for display PCB LED’s) 26 V‐2A ...
- Page 27 CIRCUIT SCHEMATICS 27 V‐2A ...
- Page 28 CIRCUIT SCHEMATICS 28 V‐2A ...
- Page 29 CIRCUIT SCHEMATICS 29 V‐2A ...
- Page 30 CIRCUIT SCHEMATICS 30 V‐2A ...
- Page 31 CIRCUIT SCHEMATICS 31 V‐2A ...
- Page 32 CIRCUIT SCHEMATICS 32 V‐2A ...
- Page 33 CIRCUIT SCHEMATICS 33 V‐2A ...
- Page 34 ACCESSORIES A pair of earth cables must be connected to the controller(s) in this user guide. A pair of cables comprises 2 off the standard cable assembly part number listed below. 1. STANDARD EARTH CABLE ASSEMBLY FOR SYSTEM 2000 99‐101‐091 2. STANDARD EARTH CABLES ASSEMBLY FOR SYSTEM 2400 99‐101‐092 Spare parts for the maintenance of earth cables are listed below: SPARE PARTS FOR SYSTEM 2000 EARTH CABLES: WELD PLUG 81‐101‐149 CABLE/m ...
- Page 35 EMAIL : sales@taylor‐studwelding.com This is to certify that the machinery listed below is designed and manufactured in conformance with all applicable health and safety regulations. This statement is invalid if any modifications are carried out on the machinery without the prior written approval of Taylor Studwelding Systems Ltd. ———————————————————————————————— DESCRIPTION OF MACHINE : Drawn Arc Studwelding Equipment TYPE : 2000E 2700E PART NUMBER : ———————————————————————————————— Applicable EC guidelines and corresponding standards: ‐ Low voltage guideline 2006/23/EC: EN60204‐1 Safety of machinery ‐ Electrical equipment of machines. ‐ EMC guidelines 2004/108/EC (electromagnetic compatibility): EN50081 ...
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