Tru-Weld TWP-2 Operating instructions

Brand: Tru-Weld

Model: TWP-2

Type: Operating instructions





OPERATION MANUAL

TWE Pin Welder

Model TWP-2

TRU‐WELDEQUIPMENTCOMPANY

6400N.HONEYTOWNROAD

SMITHVILLE,OHIO44677

(330)669‐2773

Revision1.4

4/25/2011

TRU‐WELDEQUIPMENTLIMITEDWARRANTY



AllgoodsproducedbyTru‐WeldEquipmentshallbewarrantedagainstdefectsincludingworkmanshipand

components.Nootherwarrantieswhetherexpressed,verbal,orimpliedwillapply.Warrantiesonlyapply

totheoriginalequipmentpurchaser.



WarrantyclaimswillbelimitedtoeitherrepairorreplacementofthedefectivematerialsbyTru‐Weld

Equipment.AttheoptionofTru‐WeldEquipmentthelocationofwherethewarrantyevaluationand

repairsaremadewillbedetermined.AllwarrantyclaimitemsreturnedtoTru‐WeldEquipmentwillbeat

thecustomer’sexpense.AttheoptionofTru‐WeldEquipmentthedefectwilleitherberepairedor

replaced.NoticemustbeprovidedtoTru‐WeldEquipmentofawarrantydefectwithin30daysthatthe

defectorfailureisincurred.Warrantiesarenottransferable.



Thiswarrantydoesnotapplyforequipmentwhichisusedimproperlyinanyfashionincludingbutnot

exclusivetothefollowing:

Equipmentwhichhasbeenmodified

Equipmentwhichhasnotbeeninstalledproperly

Equipmentwhichhasbeenusedforpurposesotherthanwhichithadbeendesigned

Equipmentwhichhasnotbeenproperlymaintained

Equipmentwhichwascontinuedtobeusedafteradefecthadbeenfound

Equipmentwhichwasdamagedinanyway



Tru‐WeldEquipmentwillneverbeliableforconsequentialdamages,loss,orexpenseoccurringdirectlyor

indirectlyfromtheuseoftheequipmentcoveredinthiswarranty.



Allcables,cablesetsandconnectorsarenotwarranted.



Two(2)yearwarrantyperiodfromdateofpurchase

SC3402PowerSupply

SC3400PowerSupply

SC2402PowerSupply

SC2400PowerSupply

SC1600PowerSupply

SC1400PowerSupply

TWE250PowerSupply

TWE321PowerSupply

TWE375PowerSupply



One(1)yearwarrantyperiodfromdateofpurchase

TWESPCPowerSupplies

TWP‐2PowerSupply



NinetyDaywarrantyperiodfromdateofpurchase

 (Excludingcablesandconnectors)

TWE70000HDArcstudgun

TWE18500MDArcstudgun

TWE19000LDArcstudgun

TWEG CDstudgun

TWEHDGHeavyDutyCDstudgun

2

CONTENTS

SectionDescriptionPages

1ProductFeatures3

2Specifications4

3ExternalFeatures5‐6

4Safety7‐9

5SetupandWelding10‐14

6TestingWeldSettings15

7InspectingTheWeld16

3



Model:TWP‐2

TheTWP‐2incorporatesthelatestsolidstatetechnologyintoacompact

andrugged,portableCDPinWelder.Thissystemhasthecapacitytoweld

pins(includingcuppedheadpins)upto10‐gaugeandCDStudsupto#10.



FEATURES

• DigitalDCvoltagereadout(allowsformoreaccurateandrepeatable

weldsettings).

• Coolingfanforincreasedefficiency.

• Dial‐downDCvoltagesetting(noneedtoturnofftheunitwhenreset‐

tingtoalowervoltage).

• Only15ampcircuitrequirement(unitfused@15amps).

• Poweroutput@lowerDCvoltagerequirements.

• Terminalconnectionsonthecapacitorareover5/8”indiameterfora

goodseatontheterminalbussbarstoincreasereliability.

• Theterminalconnectionsonthecapacitorhave1/4‐28socketsetscrews

insertedintoeachone.Thesocketsetscrewisusedtomaketheconnec‐

tiontothebussbar.Thiseliminatesdamagingthethreadsinthealumi‐

numconnectorsofthecapacitor,ensuringasolidconnection.

• Rigidinternalconstructionconnectingtheentireinternalunittothe

frontandrearpanelsminimizestheopportunityofthecomponents

cominglooseduringhandlingoroperations.

• TheTWE‐PinWelderismountedinaruggedoutercaseforgreaterdura‐

bility,texture,andappearance.

• TheTWE‐PinWelderweighsinatabout12.5poundsforeaseofcarrying.

• Comfortableshoulderstrapisoptionalwiththeunit.



PRODUCT FEATURES

4



PRODUCT SPECS

SPECSTWE‐PINWELDER

SIZE12.5”Lx10.1”Wx6.0”H

315mmx255mmx150mm 

WEIGHTApprox.12.5lbs.

WELDRANGE

WeldPins‐Upto10gauge

CDStuds‐Upto#10

DUTYCYCLE16‐20pinsperminute

PRIMARYPOWER110VAC@50/60Hz15Ampcircuitor220

VAC@50/60Hz7.5Ampcircuit

CHARGEVOLTAGE35‐110VDC

OperationalandSafetyFeatures

• LEDVoltageMeter

• SafetyShutdown

• CoolingFan

• Front‐PanelInformationalLED’s

• Dial‐Downweldvoltagecontrol

**Specificationsaresubjecttochangewithoutpriornotification.

5



FRONTPANEL



TOPOPENVIEW



EXTERNAL FEATURES

LEDDisplay

VoltageSelector

Weld‐ReadyIndicator

Capacitor

6

SIDEVIEWS



EXTERNAL FEATURES

StudGunControlCableCon‐

nection

StudGunWeldCableCon‐

nection

GroundCableConnection

ON/OFFSwitch

15ampCircuitBreaker

7



PROTECTYOURSELFANDOTHERS!

Readthesafetynoticesbeforeusingwelder.



ELECTRICAL

Noportionoftheoutercoveroftheweldingcontrollershouldberemovedbyany‐

oneotherthanqualifiedpersonnel.Alwaysdisconnecttheunitfromthemainpower

priortoremovingcover.

• Thisequipmentcontainsatransformerpowersupplysystem,whichisenergized

byACcurrentandtransformstheACtoDCcurrent.Duetopotentialdangerous

electricalinputandoutputtheequipmentmustbedisconnectedfromallincom‐

ingpowerwhenservicing.

• Capacitorsstoreelectricalenergy.Checkforresidualchargebeforeperforming

anymaintenance.

• Donotusefluidstocleanelectricalcomponentsasthesemaypenetratetheelec‐

tricalsystemandcauseshorts.



Connectionoftheunitintoservicemustbeinaccordancewiththesetupprocedures

asdetailedinthismanual.Operationofthisequipmentmustbeinaccordancewith

alllocal,regional,andnationalsafetycodes.



SAFETY

8



FIRE

Duringwelding,smallparticlesofhotmetalcanbeexpelled.Ensurethatnocombus‐

tiblematerialsareneartheweldingarea.



PERSONALSAFETY

Arcrayscanburnyoureyesandskin.Wearprotectiveclothingandeyeprotection

whenwelding.

Loudnoisesfromweldingcandamagehearing.Wearearplugsorotherprotective

gear,ifapplicable.

Fumesandgasesexpelledduringweldingcanbehazardoustoyourhealth.Make

sureweldingisdoneinawell‐ventilatedarea.

Hotmetalsplattercancausefiresandburns.Wearprotectiveclothing,freeofcom‐

bustiblematerials.Haveafireextinguishernearbyandknowhowtouseit.

MAINTENANCE

Allcablesmustbeinspectedregularlytoensurethatnodangerexistsfromwornor

damagedinsulationorunsafeelectricalconnections.Takespecialnotetothecables

nearthestudgun‐thisiswheremaximumwearoccurs.

Worncablesnotonlyproduceinconsistentwelds,butcanoverheatorspark.



SAFETY

FIRE HAZARD

FROM SPARKS

9



TRAINING

Useofthisequipmentmustbelimitedtoauthorizedpersonnelonly.Theymustbe

adequatelytrained,andhavereadandunderstoodeverythinginthismanual.The

manualmustbeavailabletooperatorsatalltimes.



INSTALLATION

Selectasitefortheequipmentwhichiscapableofsupportingtheweightofthe

equipment,whichisclearfromtrafficrouteswherepeoplemaytripovercables,or

theymaybedamagedbyotherequipmentorvehicles.

Donothangconnectingcablesoversharpedgesorhavenearheatsources.

DISPOSAL

Theequipment,initsentiretyorascomponents/partsmaybedisposedofasgeneral

industrialwasteorscrap.Noneofthecomponentsusedinthemanufacturingofthe

CDWeldersaretoxic,carcinogenic,orotherwiseharmfultoyourhealth.



SAFETY

AUTHORIZED

PERSONNEL ONLY

10

CONNECTINGTHEWELDINGLEADS

Connectthestudgunweldcableintothegunterminalsocketonthesideofthe

weldingunit.

***NOTE‐thecableendplughasaflatwhichalignswithadotonthepanelmount

socket.Securetheconnectorintothepanelmountsocket,andthenturnitclockwise

untilitlocksintoproperposition.Failuretodosocouldresultindamagetothecon‐

nector.







Connecttheweldguncontrolcableintothecenterpanel2‐pinsocket.

***NOTE‐theplughasalargepinandasmallpinthatmatchthesocketontheunit.

Thisistopreventincorrectconnections.Pushtheplugfirmlyintothesocketand

twistclockwisetosecuretheplugintothecorrectposition.



ConnecttheGroundCableintothegroundterminalsocketonthesideoftheunit.

SET-UP AND WELDING

StudGunWeldCableConnection

GroundCableConnection

StudGunControlCableConnection

11

CONNECTINGTHEGROUNDCLAMP

Attachtheclampoftheweldinggroundleadtotheworkpiece.Priortosecuringthe

clamp,makecertainthatthecontactareaisfreeofrust,paint,grease,oranyother

impuritiestoensureagoodgroundconnection.



SET-UP AND WELDING

12

SELECTINGTHEPROPERSTUDCOLLET(STUDHOLDER)

Thecolletisselectedtotheproperdiameterthatyouarewelding.

Therearethreestylesofcollets;

• The“B”colletwhichisatwo‐pieceassembly(colletandinsert).Theinsertdeter‐

mineshowmuchofthestudisengagedinthecollet.

• TheCI(ColletInsert)whichisasinglepartandtheamountofthestudthatisen‐

gagedispredetermined.

• StandardAdjustableChuckshaveanadjustableinternalscrewtomanuallyadjust

fortheengagementofthestud.

Thechoicebetweenthesesystemsisusuallyamatterofpersonalpreference.



Insertingtheselectedcolletintothestudgunisasimpletask.Placethecolletinto

thefrontholderofthestudgunandsetthelockingscrewstoholditinplace.

Afterinsertingthecollet,mountthetwolegsandfootpieceontothestudgun.The

colletshouldbecenteredthroughtheopeningofthefootpiece.



Whenthelegsandfootpieceareinplace,insertthestudtobeweldedintothecol‐

let.Adjustthelegandfootpiecebyslidingitintopositionuntilapproximately1/8”

ofthestudprotrudesfrombeyondthefootpiece.Locklegsinplacewiththeset

screws.

SET-UP AND WELDING

FootPiece

Collet

LegPiece

13

SELECTINGTHESPRINGLOAD

Theproperspringpre‐loadsettingonthestudgunwillvarydependingonthese‐

lectedapplication.Generalsrulesofapplicationwouldbe;mildsteelorstainless

steelusuallyinthe1to2range,dependingonthestuddiameterandthethicknessof

thebasematerial.Aluminumandothernonferrousmetalswouldrequiresettings

from3to5dependingonthediameterofthestudandbasematerialthickness.



Thisspringpre‐loadadjustmentismadebyturningthescrewinsertinthebackofthe

studgunwithascrewdriver.Onthebottomofthebackcapofthestudgunisthe

indicatornumbered1thru5,whichwillshowyouthetensionsettingduringthead‐

justment.

SET-UP AND WELDING

AdjustmentScrew

TensionIndicator

14

READYFORWELDING

Whenyouhavecompletedallofthepreviousstepstoprepareforwelding,including

connectingthestudgunandgroundcablestotheunit,attachingthegroundcable(s)

totheworkarea,settingupandadjustingthestudgunfortheselectedstuddiame‐

terandmaterial,youcannowpoweronthewelder.







ThecontrollerON/OFFswitchislocatedontherearoftheunitintheupperright

handcorner.Belowthisswitchisthe15ampcircuitbreakerforthesystem.



VOLTAGESELECTION

• Selectingtherequiredweldvoltageisachievedbyturningtheselectorknob.The

voltagerangeisfrom35VDCto110VDC.

• Thevoltageisdeterminedbythediameterofthestudandthebasematerial.The

unitislabeledwithrecommendedvoltagesettingsforvariousapplications.

• Finetuningthevoltagetomeetyourrequirementforyourspecificapplicationis

recommended.



SET-UP AND WELDING

ON/OFFSWITCH

15ampCircuitBreaker

VoltageSelectorLEDDisplay

15

TESTINGYOURSETTINGS

Whenyouhaveperformedallofthepresetsasdiscussedinthismanual,itisrecom‐

mendedthatyouperformseveraltestweldswiththesamediameterstudandbase

materialthatyouwillbeusing.Thiswillverifythatallofthesettingsarecorrectto

theresultsyoudesire.Weldingisdonebyplacingthestudintothecollet,andpress‐

ingthestudguntotheworkpiece,compressingthespring.Thisiswhythestudmust

protrudebeyondthefootpieceatleast1/8”.

Holdingthegunperpendiculartotheworkpiece,andaligningthestudtothedesired

positionontheworkpiece,pressdownsothatthefootpieceisflushwiththework

piece(springcompressed),anddepressthetrigger.



Whenremovingthestudgunfromtheweldedstud,alwaysliftthestudgunvertically

fromtheweldedstudinordertomaintainthepropertensionofthecollet.Spreading

thecolletwhenliftingthestudgunfromtheweldedstudwillshortenthelifeofthe

colletandwilleventuallycreateanundesirableweld.



TESTING WELD SETTINGS

16

INSPECTINGTHEWELD

Visuallyinspecttheweld.Agoodweldwillresultinanall‐aroundweld,withasmall

visibleamountofweldsurroundingtheflangeofthestud.Toomuchsplatterandthe

weldistoohot,lowerthevoltage.Nosplatterandtheweldistoocold,increasethe

voltage.

Ifyougetweldflashtoonesideofthestudasopposedtoanevenamountaround

thebaseoftheflange,thisiscalled“arcblow”,andcanbesolvedbyrepositioning

thegroundclamporusingadualgroundclamp.



Properweldedstudscanbetestedbyeithertorquingorbendingthestud.The

weldedflangeofthestudshouldstayinplaceusingeithermethod,eventhoughthe

threadedportionofthestudbreaks.Ifthebasematerialisverythin,thenafullslug,

thediameteroftheflangewillpullfromthebasemetalforaproperlyweldedstud.



SET-UP AND WELDING

Tru-Weld TWP-2 Operating instructions

Brand: Tru-Weld

Model: TWP-2

Type: Operating instructions

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Tru-Weld TWP-2 Operating instructions

Tru-Weld TWP-2 Operating instructions

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