Taylor 800DA Bedienungsanleitung
V-21A
OPERATING GUIDE
FOR
TYPE 800DA
DRAWN ARC CONTROLLER
TAYLOR STUDWELDING
SYSTEMS LIMITED
V-21A
INDEX
2
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.
29 CIRCUIT SCHEMATIC - WIRING.
30 CIRCUIT SCHEMATIC - DISPLAY PCB.
31 ACCESSORIES.
32 DECLARATION OF CONFORMITY.
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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 information will help
with any technical assistance you may require:
PURPOSE AND CONTENT OF THIS GUIDE
This guide has been written for :
• The personnel of the end-user responsible for the installation and maintenance of the
controller.
• The operator of the welding controller.
This guide contains information relating to :
• Installation and connection.
• Operation.
• Technical specifications and parameters.
• Spare parts.
CONTROLLER SERIAL No.
DATE PURCHASED.
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USEFUL INFORMATION
4
FURTHER INFORMATION
Should you require additional technical information, 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 information which is a pre-requisite for safe Operation
of the equipment. The operating personnel must be able to consult this guide when
necessary. In the interests of safety, make this guide available to your personnel in good
time.
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.
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.
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IMPORTANT SAFETY INFORMATION !
5
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.
Installation must be according to the setting up procedure detailed on page 11 of this guide
and must be in line with national, regional and local safety codes.
2. FIRE
During welding small particles of very hot metal are expelled. Ensure that no combustible
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 protection.
Fumes and gases can seriously harm your health. Use the equipment only in a suitably
ventilated area. If ventilation is inadequate, then appropriate fume extraction equipment
must be used.
Hot metal spatter can cause fire and burns. Appropriate clothing must be worn. Clothing
made from, or soiled with, combustible materials must NOT be worn.
Have a fire extinguisher nearby and know how to use it.
Magnetic fields from high currents can affect heart pacemakers or other electronically
controlled medical devices. It is imperative 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 insulation or from unsound electrical connections. 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 fire.
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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 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. LIMITATIONS OF USE
We recommend the use of movement aids such as a sack-cart or wheeled dolly when
moving the unit. The mass of the welding controller is 32kg and as such is suitable for
limited manhandling e.g. final positioning at the place of work. The controller is not
suitable for use in rain or snow or in an environment with increased risk of electric shock.
7. 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).
8. INTERFERENCE
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.
9. 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.
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INTRODUCTION TO STUDWELDING
7
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.
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
cycle stud welding. Although no ferrule is employed, it is recommended practice in short
cycle welding to employ a suitable shielding gas to reduce the amount of porosity in the
completed weld and improve weld quality.
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GUIDE TO EXTERNAL FEATURES
8
FRONT PANEL
1. CARRYING HANDLE
2. MAINS ON/OFF SWITCH
3. VENTILLATION HOLES ! DO NOT OBSTRUCT !
4. WELDING EARTH CONNECTION SOCKET
5. CONTROL PANEL SEE PAGE 9
6. SHIELDING GAS OUTLET SOCKET
7. PISTOL CONTROL CONNECTION SOCKET
8. PISTOL WELDING CONNECTION SOCKET
1
2
3
4
5
6
7
8
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GUIDE TO EXTERNAL FEATURES
9
CONTROL PANEL
1. WELDING TIME SETTING PUSHBUTTON
2. WELDING INDICATOR - GREEN
3. WELDING TIME/GAS PURGE TIME DISPLAY WINDOW
4. PISTOL TRIGGER ACTUATED INDICATOR - YELLOW
5. ADJUSTER KNOB
6. GAS PURGE TIME SETTING PUSHBUTTON
7. GAS FLOWING INDICATOR - GREEN
8. STUD TO WORKPIECE CONTACT INDICATOR - YELLOW
9. PISTOL LIFT COIL ENERGISED INDICATOR - YELLOW
10. SUPPLY FAULT INDICATOR - RED (INDICATES LOSS OF PHASE)
11. CONTROLLER OVER TEMPERATURE INDICATOR - RED
1 2 3 4 5
6 7 8 9 10 11
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GUIDE TO EXTERNAL FEATURES
10
BACK PANEL
1. RATING/SERIAL PLATE
2. SHIELDING GAS INLET
3. 3 Ph MAINS CABLE INLET GLAND
4. VENTILLATION GRILLE ! DO NOT OBSTRUCT !
1 3
2 4
Inhaltsverzeichnis
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