Section Fourteen

Stud welding
Introduction to Stud Welding 366

Taylor Capacitor Discharge Welders 368

Taylor Drawn Arc Welders 370

Stud Sizes & Part Numbers 375

365

SECTION FOURTEEN – STUD WELDING
There are three different types of stud welding:
Capacitor Discharge (CD) ….Short Cycle (SC)…..Drawn Arc
(DA)
They are complimentary and should not be regarded as
alternatives.
With each method, a weld stud is held in the handtool or
production head then presented squarely to the workpiece.
The three processes work as follows …
Capacitor Discharge M2.5 - M10
Energy is stored in a bank of capacitors charged to a preset
voltage determined by the type of stud and parent material.
When triggered, energy discharges as a high current pulse,
melting the pip to produce an arc. Spring pressure forces the
stud onto the molten surface to ensure complete fusion across
the flange.
The weld duration is under 4 milliseconds.
Drawn Arc M5 - M25
Current level and duration are determined by the stud diameter.
Triggering produces a pilot arc and the stud lifts to a preset
height. The main arc melts the end of the stud producing a
molten pool in the material. Return spring pressure forces
the stud into the molten pool. A ceramic ferrule contains and
shapes the weld fillet; this arc shield is not re-usable. The weld
duration is between 100 – 10’000 milliseconds.
Short Cycle M2.5 - M8
A transfer rectifier supplies a fixed current power source.
Triggering produces a pilot arc and the stud lifts to a preset
height. The main arc melts the end of the stud, producing a
molten pool in the parent material. Return spring pressure then
forces the stud into the pool. Using a shielding gas reduces
weld spatter especially with stainless steel.
The weld duration is between 10 – 100 milliseconds
The Capacitor Discharge 4-Step Process
1. The stud pip is placed in contact with the workpiece.
2. Upon triggering, the stored energy is discharged as a high
current pulse melting the pip and producing an arc.
3. Return spring pressure forces the stud in to the molten
surface area to give complete fusion across the flange.
4. The stud is welded in place. No back-marking or burn
discolourations.
The Application
CD is ideal for thin gauge, cold rolled sheet where reverse
marking can be minimized or eradicated. Penetration into the
workpiece is minimal.
366
Parent Material
For CD the sheet can be as thin as 0.7mm Mild Steel, Stainless
Steel, Aluminium Alloy and Lead-free Brass. Sheet surfaces
should be clean and flat, with the stud end must have precise
pip and cone.
CD Equipment
CD controllers are lightweight and hand-portable and have
lower purchase and operating costs than SC and DA systems.
These machines are single phase 230/110 volt 50Hz.
Advantages
Low stud costs.
Low cost equipment.
The fast process is ideal for production systems from simple
bench mounted to high speed automatic CNC.
Easy to arrange jigs
No ferrules, shielding gas and clean welds
No finishing required
The Drawn Arc 4-Step Process
1. Current and weld time is preset to suit the diameter to be
welded
2. The stud is then placed on the plate, and upon triggering a
pilot arc occurs as the stud lifts to a preset height.
3. The main arc then melts in the weld end of the stud and
creates a molten pool in the plate.
4. Return spring pressure forces the stud into the molten pool.
The ferrule contains the metal and shapes the weld fillet.
The Application
Very strong penetrative welds are achieved with this process.
The ferrules are required to contain and shape the molten
metal. The weld end of the stud is covered with flux.
Stud / Material / Power
Stud diameter 3mm to 30mm
Material from 2mm and above
Power requirements 3phase 230/380/415 Volt
The Advantages
Burns through parent material laminations and tolerates
surface curvature and imperfections e.g. light rust, scale grease
and some coatings. The DA process gives neat and controlled
weld fillet.
The only method of studwelding large diameter studs. This
process also lends itself to multiple applications
The Short Cycle 4-Step Process
1. A transfer rectifier supplies a fixed current power source
2. Triggering produces a pilot arc and the stud lifts to a preset
height
3. Return spring pressure forces the stud into the molten pool
4. Using a shielding gas reduces weld spatter especially with
stainless steel.
The Application
Short cycle gives greater penetration into the workpiece than
the CD process. When the surface is uneven and the DA would
burn through the parent material, then the SC should be used.
Parent Material
The sheet thickness for SC should be greater than 1.5mm. This
process can also be used with Stainless Steel. More suitable
than CD where surface is uneven, coated with oxide, mill scale
or dirt.
SC Equipment
Medium weight and hand portable controllers
Lower cost than DA but more than CD
Power requirements three phase 380 / 415 Volt
Advantages holes to be drilled and works loose. All of these processes are

SECTION FOURTEEN – STUD WELDING

Low cost studs slow, unsightly, require reverse access and need cleaning and
finishing.
Greater stud design and flexibility due to no pip required on the
weld end Typical applications using Studwelding
Equipment can be bench mounted and automated. Electronics and Electronics
Tolerates surface irregularities and easy to jig with no ferrules. Area
The NEW Way Control and security equipment, mechanical instruments,
office automation, data transmission, communications, test
Replacing Inserts equipment
Studwelding replaced inserts in these applications resulting in Application
faster productions and stronger joints. Thinner sheets could
now be used and with no reverse marking, corrosion was Mounting components on panels and in cabinets
eliminated as moisture ingress was prevented. Earthing components, bonding doors and panels
Replacing Drilling & Tapping Fixing wiring looms
Studwelding allowed this manufacturer to speed up production Fixing fascia panels, mounting switches, push buttons and
considerably, as previously he had to leak test every through instruments, mounting PCB’s
drilled and tapped hole. An alternative solution of using Mechanical
thicker flanges would have resulted in additional time and cost
implications. Area
Replacing Through Bolting Material handling and conveyors, lifts, metal furniture,
transportation, construction, and general machinery
One component became tamper-proof and a clean design
was the biggest benefit on another. One third of a part. The Application
sheet guage was reduced and leakage was prevented. Fixing cover plates and maintenance inspection hatches,
Finally studwelding solved the problem of loose bolts and attaching machinery guards, fixing hydraulic, air, gas and water
inaccessibility to the bolt head after assembly. tanks, lines and hoses
Replacing Back Welding Heating and Ventilation
Here production increased tenfold when studwelding replaced Area
a back-welding process. With no need to grind the top surface Domestic and industrial boilers, air conditioning and ventilation
flat and polish off excess material and burn marks, time saved units, refrigeration systems
was significant! Reject components were eliminates with Application
additional cost savings.
Attaching flanges, covers and hatches, mounting fluid
Replacing Resistance Welding chambers, fixing burners and heating elements, securing pipes
Here the studwelding process removed a bottleneck by not and insulation material
having to take the biggest component to a large resistance Decorative and Consumer
welding machine. Replacing soldering cured a corrosion
problem caused by a solder flux. Some components which Area
were previously brazed sustained damage because of the long Signs, nameplates, panels, badges, emblems, jewellery,
heat cycle. kettles, saucepans
The OLD Way Application
Pressed Inserts Fixing signs, plates, panels, badges, attaching pins, findings
and clasps to jewellery, attaching feet to kettles and handles to
Inserts can work loose, crack paint and leave stains. Holes pans
need to be punched then deburred in parent material,
weakening it. The reverse side is not always left flat, and the Miscellaneous Industrial
insert is visible and unsightly. The resulting joint cannot always Area
be guaranteed leak proof. Catering and food processing, insulation and fireproofing
Drilling and Tapping Application
Drilling and Tapping are a very slow processes requiring thicker Hygienic fixing of legs, brackets and stiffener strips to counter
parent material to achieve full joint strength. Drills and taps get and table tops.
broken and fasteners can vibrate loose. Through drilled holes Securing acoustic insulation, fixing fireproofing material
need sealing and blind holes need clearing out. • SHIPBUILDING
Back Welds • LIGHT INDUSTRY
Back welding is a slow, messy and inaccurate process, where • INSULATION INDUSTRY
holes are required into which the fastener must be precisely • MACHINE CONSTRUCTION
positioned. The biggest disadvantage is having to grind or • SWITCHGEAR TRANSFORMERS
polish off excess material or burn marks on the reverse side. • AUTOMOTIVE INDUSTRY
Through bolting • ENVIRONMENTAL ENGINEERING
• FABRICATORS
Through bolting is not tamper proof and is a cumbersome and • CONSTRUCTION INDUSTRY
slow process requiring two-handed assembly with access from
both sides. Holes weaken the parent material and leakage
stains from the unsightly bolt heads are common.
Projection and Resistance
Welding means taking a component to fixed equipment, plus
replacing electrodes and having unnecessarily high power
consumption costs. Solder and brazing requires clamping
and causes distortion. Riveting is untidy, irreversible, requires
367
 TAYLOR CAPACITOR DISCHARGE STUDWELDING SYSTEM

CDM CAPACITOR DISCHARGE CDM RANGE – CONTROLLER

SECTION FOURTEEN – STUD WELDING

STUDWELDING EQUIPMENT FEATURES

RANGE • Compact, lightweight portable
machine
Compact, portable Capacitor Discharge
• Strong, robust construction
equipment designed to weld up to
• Rapid welding action reduces weld
10mm diameter studs. With its simple
time
and robust construction the CDM
• Super fast recharge time improves
range offers an economical and reliable
profitability
method of fixing Mild Steel, Stainless
• Easy adjustment of capacitor voltage
Steel, Aluminium and Brass studs. Fast
• LED displays allow easy monitoring of
and accurate, the CDM range gives you
functions
better weld results.
• Quality and reliability from Taylor
Designed and built to exacting
Studwelding Systems Limited
standards and meets all required
• Welds Mild Steel, Stainless Steel,
standards, the CDM range is CE and
Aluminium and Brass
C-TICK marked.

Controller
Mains Input 115 and 230V AC, 50 - 60Hz, 1 Phase
Input Power 1.8KVA
Input Fuse Rating 16A at 115V, 19A at 230V
Output Voltage 35 - 200V
Output Power Source Electrolytic Capacitors
Weld Rate 10 - 50 Studs per minute
Weld Range 2 - 10mm
Enclosure Class IP31 Protection

Model CDM8 CDM8 CDM9 CDM9 CDM10 CDM10

Variant Contact Lift Gap Contact Lift Gap Contact Lift Gap
Nominal Capacitance 66’000mfd 66’000mfd 99’000mfd 99’000mfd 132’000mfd 132’000mfd
Welding Range Mild Steel 2 - 8mm 2 - 8mm 2 - 10mm 2 - 8mm 2 - 10mm 2 - 10mm
Welding Range Stainless Steel 2 - 8mm 2 - 8mm 2 - 8mm 2 - 8mm 2 - 10mm 2 - 10mm
Welding Range Aluminium 2 - 6mm 2 - 6mm 2 - 6mm 2 - 8mm 2 - 6mm 2 - 8mm
Welding Range Zintec 2 - 6mm 2 - 6mm 2 - 8mm 2 - 8mm 2 - 8mm 2 - 8mm
Weight 16.00KG 16.00KG 17.50KG 17.50KG 18.50KG 18.50KG
368
TAYLOR CAPACITOR DISCHARGE STUDWELDING SYSTEM

SECTION FOURTEEN – STUD WELDING

Contact Contact with offset chuck Contact with extended leg assembly

Model Contact Lift Gap

Welding Range 2mm to 10mm 2mm to 10mm
Stud Length Range Standard - up to 35mm Standard - up to 35mm
Extended - Any Length Extended - Any Length
Handtool Length 202mm 185mm
Cable Length 3metres 3metres
Handtool Weight 1.90kg 2.00kg

CONTACT HANDTOOL FEATURES MINI CONTACT HANDTOOL

• Designed for lightness and balance FEATURES
• Minimizes operator fatigue • Designed for use where access is
• Comfortable and easy to use limited
• Body made from impact resistant,
high strength Verton MICRO CONTACT HANDTOOL
• Accessories available to solve specific FEATURES
location problems • Designed for use where access is
LIFT GAP HANDTOOL FEATURES very limited
• Used in conjunction with standard
• Designed for lightness and balance Contact handtool
• Minimizes operator fatigue
• Comfortable and easy to use
• Body made from impact resistant,
high strength Verton
• Accessories available to solve specific
location problems
• Up to 5mm of lift available

Mini Contact Handtool Micro Contact Handtool

Welding Range 2mm to 10mm Welding Range 2mm to 8mm
Stud Length Up to 25mm Stud Length Up to 25mm
Handtool Length 70mm Handtool Length 50mm
Handtool Weight 1.45kg Handtool Weight 0.30kg

Lift gap with nose cone assembly Mini contact Micro contact
369
 TAYLOR DRAWN ARC STUDWELDING SYSTEM

SYSTEM 800E • Recessed front and back panels

SECTION FOURTEEN – STUD WELDING

protect controls and weld sockets

Compact, manoeuverable Drawn Arc • Twist and lock weld plugs and sockets
equipment designed to weld up to 12mm • Handtool can use any UK or
diameter reduced base studs. With its European chucking system
simple, robust construction the System • Gun lift test facility
800 offers an economical and reliable • Chuck saver circuit fitted
method of fixing Mild Steel and Stainless • Fitted with gas facility
Steel studs. • Welds Short Cycle Drawn Arc
Fast, accurate and easy to operate,
the System 800 gives you better weld Controller 800DA
results. Welding Stud Range 3mm to 10.8mm
Designed and built to exacting Mains Input 400V AC, 50Hz, 3
standards and meets all required Phase
standards, the System 800 is CE and
C-TICK marked. Input Fuse Rating 32A
Max. KVA Rating 30KVA
SYSTEM 800 – CONTROLLER
Welding Current 800Amps
FEATURES (10% cycle)
• Robust and compact design housing Welding Time 20 - 500
all components in one cabinet (m/sec)
• Lightweight and portable Welding Rate 20 - 3/min
• Soak tested components used, All
No-Load Voltage 58V DC
systems undergo extensive durability
tests Class Protection IP23
• Microcomputer controlled Cooling Fan
• Constant weld current Transformer H
• Infinitely adjustable welding time Insulation Class
• Solid state switching Dimensions 520 x 230 x 280mm
• Visual time display
Weight 32kg
• Constant air cooling

DA7 HANDTOOL FEATURES HANDTOOL TECHNICAL

• Designed for lightness and balance SPECIFICATION
• Comfortable to use, minimizes Model DA7
operator fatigue Material Verton
• Made from impact resistant, high
Welding Range 3mm to 12mm
strength Verton
• Accessories – Various accessories/ Stud Length Standard legs - up to
attachments are available to solve 100mm
specific problems Extended legs - up to
• Extensions are available for both 100mm
handtool and earth cables Cable Length 5metres
• Possible to weld up to 12mm standard Cable Size 25mm sq
Drawn Arc studs Handtool Weight 1.20kg
(excluding Cable)
Dimensions 205 x 140 x 62mm

DA8 HANDTOOL FEATURES HANDTOOL TECHNICAL

• Lightweight small fixed mini pistol SPECIFICATION
• Used to weld Short Cycle studs Model DA8
• Possible to weld up to 12mm standard Material Verton
Drawn Arc Studs
Welding Range 3mm to 10mm
• Supplied to weld with gas if required
Stud Length Standard legs
- 35mm
Extended legs - any
length stud
Cable Length 5metres
Cable Size 25mm sq
Handtool Weight 0.90kg
(excluding Cable)
Dimensions 185 x 130 x 40mm
370
TAYLOR DRAWN ARC STUDWELDING SYSTEM

SYSTEM 1200E • Thermostatically controlled air cooling

SECTION FOURTEEN – STUD WELDING

• Recessed front and back panels
Compact, manoeuverable Drawn Arc protect controls and weld sockets
equipment designed to weld up to 16mm • Twist and lock weld plugs and sockets
diameter studs. With its simple, robust • Handtool can use any UK or
construction the System 1200E offers an European chucking system
economical and reliable method of fixing • Gun lift test facility
Mild Steel and Stainless Steel studs. • Chuck saver circuit fitted
Fast, accurate and easy to operate, the • Fitted with gas facility
System 1200E gives you better weld • Welds Short Cycle Drawn Arc
results.
Designed and built to exacting
standards and meets all required
Controller 1200E
standards, the System 1200E is CE and
C-TICK marked. Welding Stud Range 3mm to 14.6mm
Mains Input 400V AC, 50Hz, 3
SYSTEM 1200E – CONTROLLER Phase
FEATURES Input Fuse Rating 65A
• Robust and compact design housing Max. KVA Rating 65KVA
all components in one cabinet
Welding Current 200 - 1200Amps
• Mounted on 4 wheels making the
(10% cycle)
machine easily manoeuverable (front
2 swivel wheels are fitted with brakes) Welding Time 20 - 1500
• Soak tested components used, All (m/sec)
systems undergo extensive durability Welding Rate 20 - 3/min
tests No-Load Voltage 95V DC
• Microcomputer controlled Class Protection IP23
• Infinitely adjustable welding current Cooling Fan
• Constant current control
Transformer H
• Infinitely adjustable welding time
Insulation Class
• Solid state switching
• Visual current and time display Dimensions 550 x 400 x 560mm
• Current reporting procedure Weight 108kg

DA2 / DA3 HANDTOOL FEATURES

• Designed for lightness and balance
• Comfortable to use, minimizes
operator fatigue
• Made from impact resistant, high
strength Verton
• Accessories – Various accessories/
attachments are available to solve
specific problems
• Extensions are available for both
handtool and earth cables

DA8 HANDTOOL FEATURES

• Lightweight small fixed mini pistol
• Used to weld Short Cycle studs
• Possible to weld up to 12mm standard
Drawn Arc Studs
• Supplied to weld with gas if required

HANDTOOL TECHNICAL SPECIFICATION

Model DA8
Material Verton
Welding Range 3mm to 10mm
Stud Length Standard legs - 35mm
Extended legs - any length stud
Cable Length 5metres
Cable Size 25mm sq
Handtool Weight 0.90kg
(excluding Cable)
Dimensions 185 x 130 x 40mm
371
 TAYLOR DRAWN ARC STUDWELDING SYSTEM

SYSTEM 1500 protect controls and weld sockets

SECTION FOURTEEN – STUD WELDING

• Twist and lock weld plugs and sockets

Compact, manoeuverable Drawn Arc • Handtool can use any UK or
equipment designed to weld up to 20mm European chucking system
diameter studs. With its simple, robust • Gun lift test facility
construction the System 1500 offers an • Chuck saver circuit fitted
economical and reliable method of fixing
Mild Steel and Stainless Steel studs. Controller 1500
Fast, accurate and easy to operate, Welding Stud Range 3mm to 20mm
the System 1500 gives you better weld Mains Input 400V AC, 50Hz, 3
results. Phase
Designed and built to exacting
standards and meets all required Input Fuse Rating 65A
standards, the System 1500 is CE and Max. KVA Rating 65KVA
C-TICK marked. Welding Current 200 - 1500Amps
(10% cycle)
SYSTEM 1500 – CONTROLLER
Welding Time 100 - 1500
FEATURES
(m/sec)
• Robust and compact design housing Welding Rate 20 - 4/min
all components in one cabinet
No-Load Voltage -
• Mounted on 4 wheels making the
machine easily manoeuverable (front Class Protection IP23
2 swivel wheels are fitted with brakes) Cooling Fan
• Soak tested components used, All Transformer H
systems undergo extensive durability Insulation Class
tests Dimensions 810 x 470 x 620mm
• Infinitely variable time
Weight 151kg
• 5 step current adjustment
• Thermostatically controlled air cooling
• Recessed front and back panels

DA2 / DA3 HANDTOOL FEATURES • Accessories – Various accessories/

• Designed for lightness and balance
• Comfortable to use, minimizes
operator fatigue
• Made from impact resistant, high
strength Verton
attachments are available to solve
specific problems
• Extensions are available for both
handtool and earth cables

HANDTOOL TECHNICAL SPECIFICATION

Model DA2 DA3
Material Verton Verton
Welding Range 3mm to 16mm 3mm to 20mm
Stud Length Standard legs - up to 100mm Standard legs - up to 100mm
Extended legs - any stud Extended legs - any stud
length length
Cable Length 5metres 5metres
Cable Size 50mm sq 70mm sq
Handtool Weight (excluding 1.90kg 1.90kg
Cable)
Dimensions 250 x 160 x 60mm 250 x 160 x 60mm
372
TAYLOR DRAWN ARC STUDWELDING SYSTEM

SYSTEM 1600E protect controls and weld sockets

SECTION FOURTEEN – STUD WELDING

• Twist and lock weld plugs and sockets
Compact, manoeuverable Drawn Arc • Handtool can use any UK or
equipment designed to weld up to 20mm European chucking system
diameter studs. With its simple, robust • Gun lift test facility
construction the System 1600E offers an • Chuck saver circuit fitted
economical and reliable method of fixing • Fitted with gas facility
Mild Steel and Stainless Steel studs. Fast, • Welds Short Cycle Drawn Arc
accurate and easy to operate, the System
1600E gives you better weld results.
Designed and built to exacting
standards and meets all required
standards, the System 1600E is CE and
C-TICK marked.
SYSTEM 1600E – CONTROLLER Controller 1600E
FEATURES Welding Stud Range 3mm to 20mm
• Robust and compact design housing Mains Input 400V AC, 50Hz, 3
all components in one cabinet Phase
• Mounted on 4 wheels making the Input Fuse Rating 65A
machine easily manoeuverable Max. KVA Rating 65KVA
(front 2 swivel wheels are fitted with
Welding Current 200 - 1600Amps
brakes)
(10% cycle)
• Soak tested components used, All
systems undergo extensive durability Welding Time 20 - 1500
tests (m/sec)
• Microcomputer controlled Welding Rate 20 - 4/min
• Infinitely adjustable welding current No-Load Voltage 95V DC
• Constant current control Class Protection IP23
• Infinitely adjustable welding time Cooling Fan
• Solid state switching
• Visual current and time display Transformer H
• Current reporting procedure Insulation Class
• Thermostatically controlled air cooling Dimensions 810 x 470 x 620mm
• Recessed front and back panels Weight 151kg

DA2 / DA3 HANDTOOL FEATURES DA8 HANDTOOL FEATURES

• Designed for lightness and balance • Lightweight small fixed mini pistol
• Comfortable to use, minimizes • Used to weld Short Cycle studs
operator fatigue • Possible to weld up to 12mm
• Made from impact resistant, high standard Drawn Arc Studs
strength Verton • Supplied to weld with gas if required
• Accessories – Various accessories/
attachments are available to solve
specific problems
• Extensions are available for both
handtool and earth cables
HANDTOOL TECHNICAL SPECIFICATION
Model DA2 DA3 DA8
Material Verton Verton Verton
Welding Range 3mm to 16mm 3mm to 20mm 3mm to 10mm
Stud Length Standard legs - up to 100mm Standard legs - up to 100mm Standard legs - 35mm
Extended legs - any stud length Extended legs - any stud length Extended legs - any length stud
Cable Length 5metres 5metres 5metres
Cable Size 50mm sq 70mm sq 25mm sq
Handtool Weight (excluding 1.90kg 1.90kg 0.90kg
Cable)
Dimensions 250 x 160 x 60mm 250 x 160 x 60mm 185 x 130 x 40mm
373
 TAYLOR DRAWN ARC STUDWELDING SYSTEM

SYSTEM 2000E / 2400E • Infinitely adjustable welding time

SECTION FOURTEEN – STUD WELDING

• Solid state switching

Robust manoeuverable Drawn Arc
equipment designed to weld large
studs up to 25mm in diameter. With
their simple construction this range of
equipment offers an economical and
reliable method of fixing Mild Steel and
Stainless Steel studs. Fast, accurate and
easy to operate, this range of heavy duty
equipment gives you better weld results.
Designed and built to all required
standards, this range of Drawn Arc
equipment is CE and C-TICK marked.
SYSTEM 2000E / 2400E –
CONTROLLER FEATURES
• Robust and compact design housing
all components in one cabinet
• Mounted on 4 wheels making the
machine easily manoeuverable strength Verton
(front 2 swivel wheels are fitted with
brakes)
• Soak tested components used, All
systems undergo extensive durability
tests
• Microcomputer controlled
• Infinitely adjustable welding current
• Constant current control
• Visual current and time display
• Current reporting procedure
• Thermostatically controlled air cooling
• Recessed front and back panels
protect controls and weld sockets
• Twist and lock weld plugs and sockets
• Handtool can use any UK or
European chucking system
• Gun lift test facility
• Chuck saver circuit fitted
• Fitted with gas facility
• Welds Short Cycle Drawn Arc
DA2 / DA3 HANDTOOL FEATURES
• Designed for lightness and balance
• Comfortable to use, minimizes
operator fatigue
• Made from impact resistant, high
• Fitted with long hydraulic damper for
shear stud welding
• Accessories – Various accessories/
attachments are available to solve
specific problems
• Extensions are available for both
handtool and earth cables

Controller 2000E 2400E

Welding Stud Range 5mm to 22mm 6mm to 25mm
Mains Input 400V AC, 50Hz, 3 Phase 400V AC, 50Hz, 3 Phase
Input Fuse Rating 100A 125A
Max. KVA Rating 85KVA 120KVA
Welding Current (10% cycle) 300 - 2000Amps 400 - 2400Amps
Welding Time (m/sec) 50 - 1500 50 - 1500
Welding Rate 30 - 4/min 30 - 6/min
No-Load Voltage 95V DC 95V DC
Class Protection IP23 IP23
Cooling Fan Fan
Transformer Insulation Class H H
Dimensions 1000 x 610 x 840mm 1000 x 610 x 840mm
Weight 313kg 385kg

HANDTOOL TECHNICAL SPECIFICATION

Model DA3 DA 4, 5, 6
Material Verton Verton
Welding Range 3mm to 20mm 6mm to 25mm
Stud Length Standard legs - up to 100mm Standard legs - up to 100mm
Extended legs - any stud Extended legs - any stud
length length
Cable Length 5metres 5metres
DA3 Cable Size 70mm sq DA4 - 70mm sq
DA5 - 95mm sq
DA6 - 120mm sq
Under Sling Length 100mm
Handtool Weight (excluding 1.90kg 2.10kg
Cable)
Dimensions 250 x 160 x 60mm 260 x 160 x 70mm

DA4, 5, 6
374
Stud sizes & part numbers

SECTION FOURTEEN – STUD WELDING

DIA LENGTH MILD 304 S/S 316 S/S ALU BRASS DIA LENGTH MILD 304 S/S 316 S/S ALU BRASS
CD THREADED STUDS - METRIC DA THREADED STUDS - METRIC
M3 6mm 2MS0306 2SS0306 3SS0306 2AL0306 2BR0306 M6 20mm 6MS0620 6SS0620 7SS0620 NA NA
8mm 2MS0308 2SS0308 3SS0308 2AL0308 2BR0308 25mm 6MS0625 6SS0625 7SS0625 NA NA
10mm 2MS0310 2SS0310 3SS0310 2AL0310 2BR0310 30mm 6MS0630 6SS0630 7SS0630 NA NA
12mm 2MS0312 2SS0312 3SS0312 2AL0312 2BR0312 35mm 6MS0635 6SS0635 7SS0635 NA NA
16mm 2MS0316 2SS0316 3SS0316 2AL0316 2BR0316 40mm 6MS0640 6SS0640 7SS0640 NA NA
20mm 2MS0320 2SS0320 3SS0320 2AL0320 2BR0320 45mm 6MS0645 6SS0645 7SS0645 NA NA
25mm 2MS0325 2SS0325 3SS0325 2AL0325 2BR0325 50mm 6MS0650 6SS0650 7SS0650 NA NA
30mm 2MS0330 2SS0330 3SS0330 2AL0330 2BR0330 55mm 6MS0655 6SS0655 7SS0655 NA NA
40mm 2MS0340 2SS0340 3SS0340 2AL0340 2BR0340 60mm 6MS0660 6SS0660 7SS0660 NA NA
65mm 6MS0665 6SS0665 7SS0665 NA NA
M4 6mm 2MS0406 2SS0406 3SS0406 2AL0406 2BR0406 70mm 6MS0670 6SS0670 7SS0670 NA NA
8mm 2MS0408 2SS0408 3SS0408 2AL0408 2BR0408 75mm 6MS0675 6SS0675 7SS0675 NA NA
10mm 2MS0410 2SS0410 3SS0410 2AL0410 2BR0410
12mm 2MS0412 2SS0412 3SS0412 2AL0412 2BR0412 M8 20mm 6MS0820 6SS0820 7SS0820 NA NA
16mm 2MS0416 2SS0416 3SS0416 2AL0416 2BR0416 25mm 6MS0825 6SS0825 7SS0825 NA NA
20mm 2MS0420 2SS0420 3SS0420 2AL0420 2BR0420 30mm 6MS0830 6SS0830 7SS0830 NA NA
25mm 2MS0425 2SS0425 3SS0425 2AL0425 2BR0425 35mm 6MS0835 6SS0835 7SS0835 NA NA
30mm 2MS0430 2SS0430 3SS0430 2AL0430 2BR0430 40mm 6MS0840 6SS0840 7SS0840 NA NA
35mm 2MS0435 2SS0435 3SS0435 2AL0435 2BR0435 45mm 6MS0845 6SS0845 7SS0845 NA NA
40mm 2MS0440 2SS0440 3SS0440 2AL0440 2BR0440 50mm 6MS0850 6SS0850 7SS0850 NA NA
50mm 2MS0450 2SS0450 3SS0450 2AL0450 2BR0450 55mm 6MS0855 6SS0855 7SS0855 NA NA
60mm 6MS0860 6SS0860 7SS0860 NA NA
M5 8mm 2MS0508 2SS0508 3SS0508 2AL0508 2BR0508 65mm 6MS0865 6SS0865 7SS0865 NA NA
10mm 2MS0510 2SS0510 3SS0510 2AL0510 2BR0510 70mm 6MS0870 6SS0870 7SS0870 NA NA
12mm 2MS0512 2SS0512 3SS0512 2AL0512 2BR0512 75mm 6MS0875 6SS0875 7SS0875 NA NA
16mm 2MS0516 2SS0516 3SS0516 2AL0516 2BR0516 80mm 6MS0880 6SS0880 7SS0880 NA NA
20mm 2MS0520 2SS0520 3SS0520 2AL0520 2BR0520 85mm 6MS0885 6SS0885 7SS0885 NA NA
25mm 2MS0525 2SS0525 3SS0525 2AL0525 2BR0525 90mm 6MS0890 6SS0890 7SS0890 NA NA
30mm 2MS0530 2SS0530 3SS0530 2AL0530 2BR0530 95mm 6MS0895 6SS0895 7SS0895 NA NA
35mm 2MS0535 2SS0535 3SS0535 2AL0535 2BR0535 100mm 6MS08100 6SS08100 7SS08100 NA NA
40mm 2MS0540 2SS0540 3SS0540 2AL0540 2BR0540 105mm 6MS08105 6SS08105 7SS08105 NA NA
50mm 2MS0550 2SS0550 3SS0550 2AL0550 2BR0550
65mm 2MS0565 2SS0565 3SS0565 2AL0565 2BR0565 M10 20mm 6MS1020 6SS1020 7SS1020 NA NA
25mm 6MS1025 6SS1025 7SS1025 NA NA
M6 8mm 2MS0608 2SS0608 3SS0608 2AL0608 2BR0608 30mm 6MS1030 6SS1030 7SS1030 NA NA
10mm 2MS0610 2SS0610 3SS0610 2AL0610 2BR0610 35mm 6MS1035 6SS1035 7SS1035 NA NA
12mm 2MS0612 2SS0612 3SS0612 2AL0612 2BR0612 40mm 6MS1040 6SS1040 7SS1040 NA NA
16mm 2MS0616 2SS0616 3SS0616 2AL0616 2BR0616 45mm 6MS1045 6SS1045 7SS1045 NA NA
20mm 2MS0620 2SS0620 3SS0620 2AL0620 2BR0620 50mm 6MS1050 6SS1050 7SS1050 NA NA
25mm 2MS0625 2SS0625 3SS0625 2AL0625 2BR0625 55mm 6MS1055 6SS1055 7SS1055 NA NA
30mm 2MS0630 2SS0630 3SS0630 2AL0630 2BR0630 60mm 6MS1060 6SS1060 7SS1060 NA NA
40mm 2MS0640 2SS0640 3SS0640 2AL0640 2BR0640 65mm 6MS1065 6SS1065 7SS1065 NA NA
45mm 2MS0645 2SS0645 3SS0645 2AL0645 2BR0645 70mm 6MS1070 6SS1070 7SS1070 NA NA
50mm 2MS0650 2SS0650 3SS0650 2AL0650 2BR0650 75mm 6MS1075 6SS1075 7SS1075 NA NA
65mm 2MS0665 2SS0665 3SS0665 2AL0665 2BR0665 80mm 6MS1080 6SS1080 7SS1080 NA NA
75mm 2MS0675 2SS0675 3SS0675 2AL0675 2BR0675 85mm 6MS1085 6SS1085 7SS1085 NA NA
90mm 6MS1090 6SS1090 7SS1090 NA NA
M8 16mm 2MS0816 2SS0816 3SS0816 2AL0816 NA 95mm 6MS1095 6SS1095 7SS1095 NA NA
20mm 2MS0820 2SS0820 3SS0820 2AL0820 NA 100mm 6MS10100 6SS10100 7SS10100 NA NA
25mm 2MS0825 2SS0825 3SS0825 2AL0825 NA 105mm 6MS10105 6SS10105 7SS10105 NA NA
30mm 2MS0830 2SS0830 3SS0830 2AL0830 NA 110mm 6MS10110 6SS10110 7SS10110 NA NA
35mm 2MS0835 2SS0835 3SS0835 2AL0835 NA
40mm 2MS0840 2SS0840 3SS0840 2AL0840 NA M12 20mm 6MS1220 6SS1220 7SS1220 NA NA
50mm 2MS0850 2SS0850 3SS0850 2AL0850 NA 25mm 6MS1225 6SS1225 7SS1225 NA NA
30mm 6MS1230 6SS1230 7SS1230 NA NA
M10 20mm 2MS1020 2SS1020 3SS1020 NA NA 35mm 6MS1235 6SS1235 7SS1235 NA NA
25mm 2MS1025 2SS1025 3SS1025 NA NA 40mm 6MS1240 6SS1240 7SS1240 NA NA
30mm 2MS1030 2SS1030 3SS1030 NA NA 45mm 6MS1245 6SS1245 7SS1245 NA NA
35mm 2MS1035 2SS1035 3SS1035 NA NA 50mm 6MS1250 6SS1250 7SS1250 NA NA
40mm 2MS1040 2SS1040 3SS1040 NA NA 55mm 6MS1255 6SS1255 7SS1255 NA NA
50mm 2MS1050 2SS1050 3SS1050 NA NA 60mm 6MS1260 6SS1260 7SS1260 NA NA
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 Stud sizes & part numbers

Other stud welding related products are available upon

SECTION FOURTEEN – STUD WELDING

DIA LENGTH MILD 304 S/S 316 S/S ALU BRASS

65mm 6MS1265 6SS1265 7SS1265 NA NA request, such as:
70mm 6MS1270 6SS1270 7SS1270 NA NA
• Speed Clips
• Insulation Pins
75mm 6MS1275 6SS1275 7SS1275 NA NA
• Shear Connectors
80mm 6MS1280 6SS1280 7SS1280 NA NA • Reduced Base Studs
85mm 6MS1285 6SS1285 7SS1285 NA NA • Projection Weld Bolts
90mm 6MS1290 6SS1290 7SS1290 NA NA • Nut Insert Connectors
95mm 6MS1295 6SS1295 7SS1295 NA NA • Personal Protection Caps
100mm 6MS12100 6SS12100 7SS12100 NA NA

M16 25mm 6MS1625 6SS1625 7SS1625 NA NA

30mm 6MS1630 6SS1630 7SS1630 NA NA
35mm 6MS1635 6SS1635 7SS1635 NA NA
40mm 6MS1640 6SS1640 7SS1640 NA NA
45mm 6MS1645 6SS1645 7SS1645 NA NA
50mm 6MS1650 6SS1650 7SS1650 NA NA
55mm 6MS1655 6SS1655 7SS1655 NA NA
60mm 6MS1660 6SS1660 7SS1660 NA NA
65mm 6MS1665 6SS1665 7SS1665 NA NA
70mm 6MS1670 6SS1670 7SS1670 NA NA
75mm 6MS1675 6SS1675 7SS1675 NA NA
80mm 6MS1680 6SS1680 7SS1680 NA NA
85mm 6MS1685 6SS1685 7SS1685 NA NA
90mm 6MS1690 6SS1690 7SS1690 NA NA
95mm 6MS1695 6SS1695 7SS1695 NA NA
100mm 6MS16100 6SS16100 7SS16100 NA NA

M20 25mm 6MS2025 6SS2025 7SS2025 NA NA

30mm 6MS2030 6SS2030 7SS2030 NA NA
35mm 6MS2035 6SS2035 7SS2035 NA NA
40mm 6MS2040 6SS2040 7SS2040 NA NA
45mm 6MS2045 6SS2045 7SS2045 NA NA
50mm 6MS2050 6SS2050 7SS2050 NA NA
55mm 6MS2055 6SS2055 7SS2055 NA NA
60mm 6MS2060 6SS2060 7SS2060 NA NA
65mm 6MS2065 6SS2065 7SS2065 NA NA
70mm 6MS2070 6SS2070 7SS2070 NA NA
75mm 6MS2075 6SS2075 7SS2075 NA NA
80mm 6MS2080 6SS2080 7SS2080 NA NA
85mm 6MS2085 6SS2085 7SS2085 NA NA
90mm 6MS2090 6SS2090 7SS2090 NA NA
95mm 6MS2095 6SS2095 7SS2095 NA NA
100mm 6MS20100 6SS20100 7SS20100 NA NA

M24 30mm 6MS2430 6SS2430 7SS2430 NA NA

35mm 6MS2435 6SS2435 7SS2435 NA NA
40mm 6MS2440 6SS2440 7SS2440 NA NA
45mm 6MS2445 6SS2445 7SS2445 NA NA
50mm 6MS2450 6SS2450 7SS2450 NA NA
55mm 6MS2455 6SS2455 7SS2455 NA NA
60mm 6MS2460 6SS2460 7SS2460 NA NA
65mm 6MS2465 6SS2465 7SS2465 NA NA
70mm 6MS2470 6SS2470 7SS2470 NA NA
75mm 6MS2475 6SS2475 7SS2475 NA NA
80mm 6MS2480 6SS2480 7SS2480 NA NA
85mm 6MS2485 6SS2485 7SS2485 NA NA
90mm 6MS2490 6SS2490 7SS2490 NA NA
95mm 6MS2495 6SS2495 7SS2495 NA NA
100mm 6MS24100 6SS24100 7SS24100 NA NA

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