Taylor DA8-A User manual

V-21A 1
TAYLOR STUDWELDING
SYSTEMS LIMITED
OPERATING GUIDE
FOR
TYPE DA8-A
DRAWN ARC STUDWELDING PISTOLS

V-21A 2
INDEX
PAGE CONTENT
3GENERAL INFORMATION
4SAFETY
5INTRODUCTION TO STUDWELDING
6MODEL VARIANTS
7SET UP & WELDING - CHUCKS
8SET UP & WELDING - STANDARD DA8-A
10 SET UP & WELDING - A1 & A2 MODELS
12 SET UP & WELDING - A3 & A4 MODELS
13 WELDING - ALL MODELS
15 COMPONENT EXPLOSION & PARTS LISTING
20 ACCESSORIES
26 EC DECLARATION

V-21A 3
GENERAL INFORMATION
MANUFACTURERS DETAILS
TAYLOR STUDWELDING SYSTEMS LIMITED
COMMERCIAL ROAD FIND US
DEWSBURY ON
WEST YORKSHIRE GOOGLE
WF13 2BD MAPS
ENGLAND
TELEPHONE :[phone]
FACSIMILE :[phone]
e-mail :[e-mail]
DIRECT SALES TEL :[phone]
INTERNET :www.taylor-studwelding.com
PURPOSE AND CONTENT OF THIS GUIDE
This guide has been wrien for :
The operator of the welding machine.
Installaon and maintenance personnel.
Purchasing personnel.
This guide contains informaon on :
Installaon and connecon
Operaon.
Technical data.
Spare parts and Accessories.
FURTHER INFORMATION
Should you require addional technical informaon, please contact us directly (details above) 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. 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 guide to the new owner. Please
immediately inform us of the name and address of the new owner, in case we need to contact them
regarding the safety of the device.
Please read this guide carefully before installaon of the machine.
Please especially observe the safety instrucons.
Taylor Studwelding Systems Limited reserves the right to amend the contents of this manual without nocaon.

V-21A 4
SAFETY
PROTECT YOURSELF AND OTHERS !
These welding pistols whilst unconnected are inert but once connected as part of a complete welding installaon may
present potenal risks and dangers. Please read and understand these safety noces.
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 plug from the socket.
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 in the appropriate operang/installaon guides for
the equipment being used and must be in line with naonal, regional and local safety codes.
2. FIRE
During welding 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 DANGER before
entering the area.
To minimise the risks of exposure to electromagnec radiaon, operators should not drape the welding cables over
their shoulders or wrap them around themselves in any way whilst using the equipment. It is also recommended that
operators route the welding earth return cables away from themselves and do not stand between the two earth return cables
during welding
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.
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 and any other applicable documentaon. This guide must be made available to all operators at all mes
and further hard copies of this guide may be purchased from the manufacturer or downloaded from our website. Measures
must be taken to prevent the use of this equipment by unauthorised personnel. Please note that Taylor Studwelding Systems
Ltd also oer, at an addional cost, personnel training packages, should a cercate of competency be required for operang/
maintenance 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 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 to 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. Non of the components used in the manufacture are toxic, carcinogenic or harmful to health.
Please note that, in line with the WEEE direcve, Taylor Studwelding Systems Ltd oers a return for disposal policy.

V-21A 5
INTRODUCTION TO STUDWELDING
When matched with an appropriate controller and earth cables, the Taylor Studwelding DA8-A
studwelding pistol is intended for precision stud welding up to 10 mm diameter 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 operaon is derived from an appropriate studwelding
controller.
Taylor Studwelding Systems Ltd controllers are modern, robustly designed and oer 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 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.
The DA8-A range of pistols are what are commonly referred to as “xed li” pistols. This is because the
pistol does not include a clutch assembly in the li mechanism. In praccal terms this means that
although the li can be user adjusted within its operaonal limits, should certain parameters change from
weld to weld, for example the studs to be welded vary in length or the surface being welded to being very
uneven, this will have an eect on the amount of li during the weld and may impact adversely on the
quality of the nished weld. Because of this, we recommend that only properly manufactured weld studs
be used and that customers should always strive to weld to at, even surfaces.
It is important to decide, based on your specic applicaon, which model variant of the DA8-A will be best
for you. For example. If you are welding standard drawn arc studs with ferrules, the standard DA8-A
would be your choice whereas if your applicaon calls for short cycle or CD type studs welding using a
template with 35mm posioning guides , the A2 would be the best choice. You could also select the A4
for this applicaon providing that the studs to be welded are under 40mm in length as this is limit for stud
length in the A3 and A4 variants. See page 6 for an outline of the dierent model variants.

V-21A 6
MODEL VARIANTS
The basic standard model of the DA8-A pistol is
shown here on the le. This model is supplied rigged
as standard to use European screw-on chucks and
for welding standard drawn arc studs with ceramic
ferrules .
Four other model variants are available, each rigged
dierently to handle dierent more specic
applicaons. These are shown below.
DA8-A
COMPLETE PISTOL PART NUMBER :
99-101-063
DA8-A1 DA8-A2
99-101-064 99-101-065
Uses standard European Uses standard European
Screw-on chucks and Screw-on chucks and
long/gas chucks. long/gas chucks.
Rigged for gas purging and Rigged for gas purging and
ed with a 30mm nose ed with a 35mm nose
piece piece
DA8-A3 DA8-A4
99-101-066 99-101-067
Uses CD type chucks Uses CD type chucks
Fied with one-piece Fied with one-piece
30mm front cap. 35mm front cap.
Can be rigged for gas Can be rigged for gas
purging oponally. purging oponally.

V-21A 7
SET UP AND WELDING - CHUCKS
Select the required weld stud on the basis of process, diameter, length and material. See
our separate catalogues entled “Drawn Arc Stock List” & "Capacitor Discharge Stock List"
which can be found by scanning the adjacent QR codes or
alternavely are available from your local Taylor stockist.
DRAWN ARC CD
Select the required chuck, appropriate to the pistol variant
and weld stud diameter. European screw-on chucks have a
female M10 mounng thread and mount directly onto the
male M10 thread on the sha of the standard A, A1 & A2
variants whilst CD type
chucks t directly into the
chuck nut on the front of
the sha of the A3 & A4 variants (a list of available chucks
of both types may be found in the accessories secon of
this guide on pages 20 - 25).
CD type chucks have an
adjustable backstop which
needs to be adjusted to
suit whatever length of
stud has been selected (up
to a maximum length of 40mm). This is because the pistol variants using the CD type
chucks have a xed length setup. The stud must be inserted fully into the chuck unl the
ange of the stud hits the face of the chuck and then adjusted out by turning the adjuster
screw unl there is an approximate gap of 3 - 4mm between the face of the chuck and the
back of the stud ange.
Euro chucks do not have any adjustment.
This is because the pistol variants using
these chucks adjust for the length of the
stud on the pistol and not in the chuck.
Instead they have a blind depth hole into
which the weld stud is loaded. If welding
with ferrules, select the appropriate size
of ferrule grip to suit the ferrules being used.

V-21A 8
SET UP AND WELDING - STANDARD DA8-A
Having selected and where necessary prepared
the chuck, it can now be ed to the pistol. To
begin, remove the foot assembly by loosening
the thumbscrews on the front end cap (chuck
ng may be accomplished without removing
the foot assembly. However, removal of the
assembly provides easier access).
Slide the chuck into bellows support and screw
the chuck into posion on the M10 mounng
thread on the front of the pistol sha.
Tighten the chuck into posion using an
appropriate wrench (usually 14mm A/F for Euro
chucks - see page 25).
IMPORTANT! Do not over-ghten chucks. This
requires only hand ghtening. Over-ghtening may result in un-warraned damage to your
pistol.
Re-fit the foot assembly by sliding into the front end cap and
tightening the thumbscrews then fit the brass ferrule grip into the
foot adaptor. Ensure the ferrule grip is an appropriate match to
the chuck fitted earlier. The ferrule grip is held in position by two
set screws positioned 180° apart in the foot adaptor. Gently
secure the ferrule grip using a 2.5mm hex key. Again, be aware
that over-tightening may damage the grip.

V-21A 9
SET UP AND WELDING - STANDARD DA8-A
With the correct stud and ferrule to be welded ed
into the chuck/ferrule grip, loosen the thumbscrews
and slide the foot assembly unl the stud is
protruding past the ferrule to the desired distance.
Once this is set, re-ghten the thumbscrews.
Remove the ferrule and check the centrality of
the stud in the ferrule grip by looking straight
down the centre of the pistol sha. If the stud
appears to be o-centre. Use a 3mm hex key to
loosen the foot screws on the foot adaptor and
re-posion the adaptor on the legs (the holes in
the adaptor are designed to allow adjustment).
Re-ghten the screws once the adjustment has
been made.
The next step is to set the required li for
welding. This must be done in three stages to
ensure that the li is set properly. Stage one is
to back the li o so that the pistol can be
properly posioned to set the li. To back the
li o, twist the rear end cap adjuster an-
clockwise unl the pistol indicator is in the MAX
posion.
Stage two is to “zero” the li. NOTE Ensure that the pistol is not connected to the
controller whilst performing this stage. To do this the pistol (with a
stud and ferrule loaded) needs to be pressed into the posion as if a
weld is about to take place with the sha moving back unl the
ferrule is hard against the surface. With the pistol held rmly in this
posion, turn the rear end cap adjuster clockwise and connue to
turn it unl it reaches the zero posion. This is the point where
further turning of the adjuster will start to force the stud forward,
liing the ferrule away from the surface. This is the zero posion.

V-21A 10
SET UP AND WELDING - STANDARD DA8-A
Stage three is to set the required li. The rear
end cap adjuster has a click detent which
allows the adjuster to stop every half-turn. This
means that each half-turn ≈ 0.5mm li.
Therefore, if 2mm of li is required, turn the
rear end cap adjuster an-clockwise 4 clicks
from the zero posion to set the li.
IMPORTANT! If any changes are made to the
seng of the pistol, the chuck, ferrule grip, stud length etc. The li may be aected and
this procedure may need to be re-executed to ensure that the required li is applied.
SET UP AND WELDING - A1 & A2 MODELS
Having selected and where necessary prepared
the chuck, it can now be ed to the pistol. To
begin, remove the foot assembly by loosening
the thumbscrews on the front end cap (chuck
ng may be accomplished without removing
the foot assembly. However, removal of the
assembly provides easier access).
Slide the chuck into bellows support and screw the chuck
into posion on the M10 mounng thread on the front of
the pistol sha.
Tighten the chuck into posion using an appropriate
wrench (usually 14mm A/F for Euro chucks - see page 25).
IMPORTANT! Do not over-ghten chucks. This
requires only hand ghtening. Over-ghtening may
result in un-warraned damage to your pistol.