Taylor i16 User manual

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OPERATING GUIDE
FOR
TYPE i16
DRAWN ARC CONTROLLER
TAYLOR STUDWELDING
SYSTEMS LIMITED

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INDEX
PAGE No. CONTENT
3USEFUL INFORMATION.
5IMPORTANT SAFETY INFORMATION.
7INTRODUCTION TO STUDWELDING.
8GUIDE TO EXTERNAL FEATURES.
11 SETTING UP AND WELDING.
15 WELDING TIME AND CURRENT SETTINGS.
16 VISUAL WELD INSPECTION.
17 WELD TESTING.
20 STUDWELDING TECHNIQUES.
23 PARTS LIST & EXPLODED DIAGRAMS.
31 CIRCUIT SCHEMATIC.
33 ACCESSORIES.
34 EC DECLARATION OF CONFORMITY.

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USEFUL INFORMATION
MANUFACTURERS DETAILS
TAYLOR STUDWELDING SYSTEMS LIMITED
COMMERCIAL ROAD
DEWSBURY
WEST YORKSHIRE
WF13 2BD
ENGLAND
TELEPHONE :[phone]
FACSIMILE :[phone]
email :[e-mail]
WEB :www.taylor-studwelding.com
SALES DIRECT TEL :[phone]
TECHNICAL HELPLINE :[phone]
You may wish to record the details of your controller below as this informaon will help
with any technical assistance you may require:
PURPOSE AND CONTENT OF THIS GUIDE
This guide has been wrien for :
• The personnel of the end-user responsible for the installaon and maintenance of the
controller.
• The operator of the welding controller.
This guide contains informaon relang to :
• Installaon and connecon.
• Operaon.
• Technical specicaons and parameters.
• Spare parts.
CONTROLLER SERIAL No.
DATE PURCHASED.

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USEFUL INFORMATION
FURTHER INFORMATION
Should you require addional technical informaon, 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 informaon which is a pre-requisite for safe Operaon
of the equipment. The operang 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 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 400V AC @ 50Hz
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 OR
IN CONDITIONS OF RAIN OR SNOWFALL.
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 guide without nocaon.

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IMPORTANT SAFETY INFORMATION !
PROTECT YOURSELF AND OTHERS !
Read and understand these safety notes.
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 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.
Installaon must be according to the seng up procedure detailed on page 11 of this guide
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. 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.
4. 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.

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IMPORTANT SAFETY INFORMATION !
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. LIMITATIONS OF USE
The mass of the welding controller is 37kg and is suitable for 2 person liing. It is ed with
appropriate carrying handles to allow liing by hand. The controller is suitable for use in an
environment with increased risk of electric shock.
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 operaon.
Do not hang connecng cables over sharp edges and do not install connecng cables near
heat sources or via trac routes where people may trip over them or they may be
damaged by the passage of vehicles (forklis etc).
7. INTERFERENCE
During welding operaons, intense magnec and electrical elds are unavoidably produced
which may interfere with other sensive Electronic equipment.
All Taylor Studwelding equipment is designed, manufactured and tested to conform the
current appropriate European standards and direcves regarding electromagnec
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”
condion.

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INTRODUCTION TO STUDWELDING
The Taylor Studwelding i16 Drawn Arc controller when matched with an appropriate pistol
and earth cables is intended for precision stud welding up to 16 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 operaon is derived from a fully micro-
processor controlled power inverter inside the controller.
Taylor Studwelding Systems Ltd pistols are modern, ergonomically designed and oer
maximum comfort in handling with minimum operator fague.
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 posion, the pistol lis 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 compleon 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 tradional drawn arc welds have a weld duraon 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 formaon of the
nal llet. 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 duraon of less than 100ms and this type of weld is referred to as short
cycle stud welding. Although no ferrule is employed, it is recommended pracce 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
FRONT PANEL
1. CARRYING HANDLES
2. MULTI-FUNCTION DISPLAY
3. INDICATOR LEDS (SEE PAGE 9)
4. WELDING EARTH SOCKET
5. VENT - DO NOT OBSTRUCT!
1
2
3
4
5
6
7
8
9
10
11
6. CONTROL KNOB/PUSHBUTTON
7. ON/OFF SWITCH
8. SHIELDING GAS INLET
9. WELDING PISTOL SOCKET
10. SHIELDING GAS OUTLET
11. PISTOL CONTROL SOCKET

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GUIDE TO EXTERNAL FEATURES
CONTROL PANEL
1. MULTI-FUNCTION DISPLAY UNIT - USED TO SELECT OPERATIONAL PARAMETERS ETC. AND
REPORT BACK INFORMATION
2. CONTACT/ERROR LED - DURING NORMAL WELDING OPERATIONS THIS LED GLOWS AMBER
TO INDICATE STUD TO PLATE CONTACT WITHOUT WHICH A WELD CANNOT TAKE PLACE. IF
AN ERROR OR FAULT CONDITION OCCURS, THIS LED GLOWS RED TO DRAW ATTENTION TO
THE OCCURRENCE. FURTHER INFORMATION IS DISPLAYED ON THE MULTI-FUNCTION DISPLAY
3. TRIGGER LED - INDICATES THAT PISTOL TRIGGER HAS BEEN ACTIVATED
4. GAS LED - INDICATES THAT SHIELDING GAS FLOW IS ACTIVATED
5. GUN LIFT LED - INDICATES THAT THE GUN LIFT HAS BEEN ACTIVATED
6. WELD LED - INDICATES THAT THE WELD CURRENT HAS BEEN ACTIVATED
7. CONTROL KNOB - INCORPORATING PUSH BUTTON FUNCTION - USED FOR INTERACTION WITH
MULTI-FUNCTION DISPLAY
1
2
3
4
5
67

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GUIDE TO EXTERNAL FEATURES
BACK PANEL
1. 4m CABLE WITH 3 Ph MAINS CONNECTOR
2. 3 Ph MAINS CABLE INLET GLAND
3. RATING/SERIAL PLATE
4. VENTILLATION GRILLE - ! DO NOT OBSTRUCT !
1
2
3
4

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SETTING UP AND WELDING
Set up the control unit at the place of work, ensuring that the
mains switch is in the OFF posion.
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. 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 unl
they lock. Failure to do this may 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 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.
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 unl
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-mounng socket are keyed to
prevent incorrect ng. Push the plug rmly home and twist
the locking ring to secure the plug in posion.
Set up the welding pistol according to the instrucons in the
operang guide supplied with the pistol.

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SETTING UP AND WELDING
If oponal shielding gas is to be used during welding. Aach the
bole supply to the controller via the front panel using a suitable
self-sealing push-on socket.
Connect the gas pipe from the pistol to the output socket on the
front panel (oponal).
If the mains supply is switched. Turn ON the mains supply.
Turn ON the controller using the switch on the front panel. The
controller will run through a start-up self-test during which the
mul-funcon display will cycle through a welcome screen and
show the current rmware version etc. also various indicators
etc. on the front panel will ash, before seling to a display
showing the last user setup. At this point the controller is ready
to use at the sengs employed during the previous operang
period.
However. If a sengs change is required it is possible to do so
from this point by pressing the control knob. This will toggle the
display. The display will show 2 opons:
->Change
Load
With the indicator (->) aligned with the word Sengs.
The 2 opons oer alternave paths to achieve the required
welding parameter set up for the job in hand. Opon Change is
used to manually select a new set of parameters for the next
welding operaon.
Whilst opon Load is used to load a set of pre-exisng welding
parameters from the controllers internal memory.

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SETTING UP AND WELDING
By rotang the control knob, select either:
->Change or Change
Load ->Load
And press the control knob to conrm selecon.
Selecng Change will take you through the following series of manual weld parameter
seng screens:
CURRENT TIME GAS SAVE
Beginning with CURRENT. Set the desired parameter value by turning the control knob then
press the control knob to lock-in the parameter and move to the next screens (TIME, GAS).
Repeat these steps to adjust and lock-in the TIME and GAS parameters. The nal screen
SAVE, invites you to save the parameters you have set into one of the 20 available memory
locaons in the controller. Select the locaon (1 - 20) by turning the control knob and
nalise the save by pressing the control knob which will return you to the normal operang
mode screen, which will now display the parameters you have set.
If you have already saved parameters in one or more of the
memory locaons, you may wish to select Load at the selecon
screen (see above). You can then select (by turning the control
knob) which of the 20 memory locaons you wish to load from
and select this parameter set by pressing the control knob. This
will load the parameters from the selected memory locaon
and return you to the normal operang screen, displaying the
loaded parameters.

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SETTING UP AND WELDING
Set up the welding pistol in-line with the operang guide
supplied with the pistol. Ensuring that there is sucient stud
protrusion and that the stud is centred in the ferrule/foot
assembly. Place the pistol perpendicular to the work piece with
the stud touching down at the desired locaon to be welded.
Press down on the pistol unl the ceramic ferrule rests rmly on
the work piece. Press the trigger to iniate the weld sequence
(see graphic below). See the secon on STUDWELDING TECHNIQUES for further advice.
Having welded the stud, draw the pistol vercally o the stud.
Failure to do this may cause the split nes 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
unl it shaers and visually inspect the weld.
For a guide to the inspecon of the welded
stud see the secons on VISUAL WELD
INSPECTION and WELD TESTING.
1. PREPARE PISTOL 2. POSITION PISTOL 3. TRIGGER. LIFT & PILOT ARC
4. MAIN ARC & FUSION 5. ARC STOPS, PISTOL PLUNGES 6. WELD COMPLETE. WITHDRAW

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WELDING TIME AND CURRENT SETTINGS
This page is intended as a guide to seng your
machine.
A set of basic formulae as dened by the Brish
Standard BS EN ISO 14555:2014 (European
Standard EN ISO 14555:2014) Annex A.2.7.2.2
and Annex A.2.7.2.4 may be used to calculate the
current and me sengs to weld any stud.
These formulae when applied to standard studs
give results shown in the table on this page. A
graphical representaon of the data is also
illustrated below.
The sengs generated in the table are only
intended as a starng point. It is possible that the sengs will give sasfactory results
without adjustment, but
in reality the quality of
the welding results is
governed by many
variable factors. These
include, most obviously,
the welding me, current
and arc-gap (pistol li) as
covered in the table, but
can also include factors
such as stud and work-
piece material type and
condion, ambient
temperature, relave
humidity, quality of
supply etc. All of these
factors can act on the
weld to change the
outcome. It is
recommended that in all
instances, you need to
carry out sample welds in
your actual condions
and environment. This
will enable you to alter
the sengs, where
necessary, to achieve
welds that are most
acceptable to you.
STUD
TYPE
ACTUAL
DIAMETER
(mm)
WELD
CURRENT
(A)
WELD
TIME
(ms)
5FB 5400 100
6RB 4.7 376 94
6FB 6480 120
8RB 6.2 496 124
8FB 8640 160
10RB 7.9 632 158
10FB 10 800 200
12RB 9.5 760 190
16RB 13.5 1100 400
WELD CURRENT - EN ISO 14555
0
200
400
600
800
1000
1200
1400
1600
1800
2000
5FB 6RB 6FB 8RB 8FB 10RB 10FB 12RB 12FB 16RB 16FB 19FB 20RB 20FB
STUD SIZE
CURRENT (A)
WELD TIME - EN ISO 14555
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
5FB 6RB 6FB 8RB 8FB 10RB 10FB 12RB 12FB 16RB 16FB 19FB 20RB 20FB
STUD SIZE
WELD TIME (s)

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VISUAL WELD INSPECTION
This page will help you to recognise a poor weld when you see one and give some of the
possible explanaons as to how it may have occurred. Your test welds should look like the
rst 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 Aer Welding). This should be correct to within + 0 / - 1 mm.
• The base llet 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, fullling the criteria above i.e. The
LAW is correct, the stud has a complete, well formed and even llet 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 : Insucient heat, causing the L.A.W. to be too long and the llet to
be underdeveloped and/or incomplete.
REMEDY : Increase the welding me (see page 13).
EXAMPLE 2
PROBLEM : Excessive heat, causing the L.A.W. to be too short and the llet to be
too large and messy, spreading out under the ferrule and/or
splashing up the threads.
REMEDY : Reduce the welding me (see page 13).
EXAMPLE 3
PROBLEM : The ferrule is not being held rmly against the work-piece and/or
the stud is binding against the ferrule.
REMEDY : Hold the pistol rmly down to the work-piece (see page 14) and
reset the alignment of the stud and ferrule (refer to your pistol
setup guide).
EXAMPLE 4
PROBLEM : Insucient stud protrusion set on the pistol and/or the stud is
binding against the ferrule.
REMEDY : Adjust stud protrusion to correct seng (refer to your pistol setup
guide).
EXAMPLE 5
PROBLEM : Poor alignment i.e. stud is not perpendicular to the work- piece.
REMEDY : Hold the pistol perpendicular to the work-piece (see page 14).
NOTE : If the misalignment is only slight and in all other aspects the weld is
good, then the weld may be salvaged by tapping straight with a so
mallet.
✓






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WELD TESTING
There are two factors which should receive special aenon in establishing visually whether or not
a stud weld is sound. These are :
• The length aer 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 aer welding, should be correct within +0/-1 mm. A word of
explanaon is perhaps needed on this point. All studs produced include a "weld allowance".
This allowance is so arranged for the dierent diameters of stud, that it will be completely
melted during the welding process, provided of course that the correct condions have been
established and the correct values of current and me are used.
• The llet 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 examinaon. It should be the aim
of every operator to produce these results.
Under normal condions a stud welded to clean mild steel plate of adequate thickness having the
correct L.A.W. and llet formaon. as described above, will be a sasfactory weld.
It should be remembered, however, that dierent applicaons or condions will produce slightly
dierent visual results, parcularly in the appearance of the llet, i.e.. Slightly rusty, dirty or oily
plate will produce blow holes in the llet, in proporon to the degree of plate contaminaon.
Welding close to some magnec obstrucon may produce uneven llet distribuon. Too much
power will produce a llet that ows too easily and is lost either up in the threads of the stud or out
through the ferrule vents, while too lile power may not melt sucient material to form a complete
llet.
It is important, therefore, to judge the degree to which these possible variaons will aect the weld
strength, but in general, provided that the L.A.W. is correct and the llet formaon is not unsightly,
a visual examinaon is all that is required.
Further tesng may be carried out on a "percentage of producon" 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 sasfactory test, as the direcon
and force behind the blows is uncontrolled, as also is the point at which the impact takes
place. The length, diameter and type of stud also have an eect on the results obtained.
• Bending the stud over by using a tube of approximately the same bore as the stud diameter.
This method is preferred to hammering, but again no conclusive evidence as to the strength
of the weld is obtained.
• Loading the stud by the use of washers / spacer and a nut unl the stud breaks. This method
is much more conclusive and should show that the weld is in fact stronger than the stud. Use
of a suitably calibrated torque wrench for this test will give an indicaon of the U.T.S.
developed by the stud material under test.

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18
WELD TESTING
2. NON DESTRUCTIVE TESTING.
Generally the most praccal way of tesng threaded stud welds, without destroying the
stud, is with the use of proof tests. A torque wrench is parcularly useful for this purpose.
Below and overleaf are some tables which you may nd useful. However, it must be noted
that :
• Formulas & data shown are intended for guidance only.
• In applicaons where control of preload is important, the torque - tension
relaonship should be determined experimentally on the actual parts involved
including any lubricants.
• The coecient of fricon (k) varies with material, surface nish 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. An-
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 gures are approximate and do not form part of any specicaon.
• Designers and speciers must sasfy themselves that the studs and materials chosen
are suitable for their parcular applicaon.
All torque gures are calculated by the formula : T = kDP
Where :T = Torque (Nm)
D = Eecve Stud Diameter (m)
k = Coecient of Fricon (0.2 used for calculaons)
Material properes: (N/mm²) (N/mm²) (N/mm²)
UTS Yield Safe
Mild Steel (4.8) 420 340 272
Stainless Steel (1.4301) 540 350 280
Note: safe loads are 80% of the yield

V-1C
19
Stud loads - Full Base Drawn Arc Studs (kN)
Torque required to reach the loads above (Nm)
Stud loads - Reduced Base drawn Arc Studs (kN)
Torque required to reach the loads above (Nm)
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 30.6 19.8 15.8
M12 x 1.75 34.6 28.0 22.4 44.5 28.8 23.1
Mild Steel Mild Steel Mild Steel Stainless
Steel
Stainless
Steel
Stainless
Steel
Thread UTS Yield Safe UTS Yield Safe
M5 x 0.8 4.9 4.0 3.2 6.3 4.1 3.3
M6 x 1.0 8.2 6.7 5.3 10.6 6.9 5.5
M8 x 1.25 20.7 16.8 13.4 26.7 17.3 13.8
M10 x 1.5 40.5 32.8 26.2 52.1 33.8 27.0
M12 x 1.75 71.0 57.5 46.0 91.3 59.2 47.4
WELD TESTING
Mild Steel Mild Steel Mild Steel Stainless
Steel
Stainless
Steel
Stainless
Steel
Thread UTS Yield Safe UTS Yield Safe
M6 x 1.0 7.2 5.8 4.7 9.3 6.0 4.8
M8 x 1.25 12.6 10.2 8.2 16.3 10.5 8.4
M10 x 1.5 20.5 16.6 13.3 26.4 17.1 13.7
M12 x 1.75 29.7 24.0 19.2 38.2 24.8 19.8
Mild Steel Mild Steel Mild Steel Stainless
Steel
Stainless
Steel
Stainless
Steel
Thread UTS Yield Safe UTS Yield Safe
M6 x 1.0 6.8 5.5 4.4 8.8 5.7 4.6
M8 x 1.25 15.7 12.7 10.2 20.2 13.1 10.5
M10 x 1.5 32.5 26.3 21.1 41.8 27.1 21.7
M12 x 1.75 56.6 45.8 36.6 72.7 47.1 37.7

V-1C
20
STUDWELDING TECHNIQUES
The operang instrucons given previously in this guide apply to the majority of general
applicaons where it is possible to use the pistol in the down hand posion and with standard cable
lengths. For many applicaons these condions do not apply and the following notes will give some
guidance as to the methods used to obtain sasfactory results for a variety of applicaons.
1. WELDING TO A PLATE IN THE HORIZONTAL POSITION.
In this posion there is a tendency for the weld metal to run to the underside of the stud during
welding, due to the acon of gravity, resulng in an uneven llet. The eect is more noceable as
stud diameter increases and generally speaking it is not recommended that studs of 12 mm
diameter and over be welded to vercal plates for this reason. The essenal requirement to obtain
sasfactory llet formaon is to use the shortest weld me possible with increased welding current.
Welding to a vercal 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 aachment can be supplied if required. Take parcular 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 operaons. Weld spaer can do a lot of damage !
Firstly, obtain sasfactory weld sengs in the down hand posion before making aempts in the
overhead posion. Since the weld metal is transferred from stud to plate in small parcles in the
down hand posion, it follows that, when welding overhead, the transfer takes place against
gravity. As with vercal welding the best results will be achieved using the shortest possible weld
me with increased welding current.
It is important that the ferrule grip, foot adapter and chuck are kept free from spaer 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 vercal or overhead posions with a damped
pistol. To prevent problems occurring, where it is possible to do so, the damping eect should be
removed or turned o.
Welding can then connue as outlined in secons 1. and 2.
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 staons and building construcon, 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 eect, reducing power. Also avoid coiling any excess cable as this will have the same eect.