SWF ACE - P100 User manual

OPERATOR’S MANUAL
ACE - P100
Pin Welder
STUD WELDING & FASTENERS INC
1032 Tennessee Blvd.
Lebanon, TN 37087
www.studweldfast.com
[phone]

CONTENTS
Descripon Pages
Warranty Informaon 1
Safety 2
Specicaons and Features 3
Product Components 4-5
Screen Operaon 6-8
Setup and Welding 9-11
CD Gun Exploded View 12

TRU-WELD EQUIPMENT LIMITED WARRANTY
All goods produced by Tru-Weld Equipment shall be warranted against defects including workmanship and components. No other war-
ranes whether expressed, verbal, or implied will apply. Warranes only apply to the original equipment purchaser.
Warranty claims will be limited to either repair or replacement of the defecve materials by Tru-Weld Equipment. The locaon of
where the warranty evaluaon and repairs are made will be determined at the opon of Tru-Weld Equipment . All warranty claim items
returned to Tru-Weld Equipment will be at the customer’s expense. At the opon of Tru-Weld Equipment the defect will either be re-
paired or replaced. Noce must be provided to Tru-Weld Equipment of a warranty defect within 30 days that the defect or failure is
incurred. Warranes 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 modied
•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 has been used aer a defect had been found
•Equipment which has been damaged in any way
Tru-Weld Equipment will never be liable for consequenal 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 covered under warranty
Two (2) year warranty period from date of purchase
● TWE250 Power Supply ● SC900 Power Supply ● SC2400 Power Supply
● TWE250CP Power Supply ● SC950 Power Supply ● SC2402 Power Supply
● TWE321 Power Supply ● SC1400Power Supply ● SC2420 Power Supply
● TWE375 Power Supply ● SC1450 Power Supply ● SC3400 Power Supply
● TW-i250 Power Supply ● SC1600 Power Supply ● SC3402 Power Supply
● TW-i250CP Power Supply ● SC1650 Power Supply ● SC3422 Power Supply
● TW-i321 Power Supply ● SC1900 Power Supply
● TW-i375 Power Supply ● SC1950 Power Supply
One (1) year warranty period from date of purchase
● TWESPC Power Supply ● TWP-2 Power Supply ● ACE-P100 Power Supply
Ninety (90) day warranty period from date of purchase
● TWEGP CD stud gun ● TWE17000 HD arc stud gun
● TWEG MD CD stud gun ● TWE18500 MD arc stud gun
● TWEHDG HD CD stud gun ● TWE19000 LD arc stud gun
WARRANTY INFORMATION
1

Read the safety noces before operang welder
Electrical
•Due to potenal dangerous electrical input and output the
equipment must be disconnected from all incoming power
when servicing. Do not operate the equipment with the outer
cover removed or with the case open.
•Capacitors store electrical energy, completely discharge before performing any maintenance.
•Do not use uids to clean electrical components as these may penetrate the electrical system
and cause shorts.
•Connecon of the unit into service must be in accordance with the setup procedures as de-
tailed in this manual. Operaon of this equipment must be in accordance with all local, region-
al, and naonal safety codes.
Fire
•During welding, small parcles of hot metal can be expelled. Ensure
that no combusble materials are near the welding area.
Personal Safety
•Arc rays can burn eyes and skin. Wear protecve clothing and eye pro-
tecon when welding.
•Loud noises from welding can damage hearing. Wear earplugs or oth-
er protecve gear, if applicable.
•Fumes and gases expelled during welding can be health hazards. Make sure welding is done in
a well-venlated area.
•Hot metal splaer can cause res and burns. Wear protecve clothing, work in an area free of
combusble materials, and have a re exnguisher nearby.
Maintenance
•All cables must be inspected regularly to ensure that no danger exists from damaged insula-
on or unsafe electrical connecons. Take special note of the cables near the stud gun, this is
where maximum wear occurs.
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 mes.
Installaon
•Select a site which is capable of supporng the weight of the equipment.
•Select a site which is clear from heavy foot trac areas to avoid tripping hazards.
•Select a site that prevents cable damage from equipment and vehicles.
•Do not hang connecng cables over sharp edges or place near heat sources.
SAFETY
FIRE HAZARD
FROM SPARKS
2

SPECS TWE-PIN WELDER
SIZE 12.5” L x 10.1” W x 6.0” H
318mm x 257mm x 152mm
WEIGHT (Power Supply Only) 10.2 lbs. (4.6kg)
WELD RANGE Weld Pins - Up to 10 gauge
CD Studs - Up to #10
DUTY CYCLE 15-30 pins per minute
PRIMARY POWER 110 VAC @ 50/60Hz 15 Amp circuit
220 VAC @ 50/60Hz 7.5 Amp circuit
CHARGE VOLTAGE 35-100 VDC
* Specicaons are subject to change without prior nocaon
Model: ACE-P100
The ACE-P100 incorporates the latest solid state technology into a compact, rugged, and portable CD
Pin Welder. This system has the capacity to weld CD pins and cupped head pins up to 10-gauge as
well as CD Studs up to #10.
Specicaons
Features
•Less than 1 second recharge me for pin welding
•Intuive Touchscreen Interface with preset values for fast, accurate, and repeatable weld sengs
•Set-Point Discharge: Unit discharges directly to a new set point without needing to discharge
completely
•Universal Input Voltage: Plug and play, no need to re-tap the machine for 110V or 220V input
voltages
•Low input voltage capability enables operaon with long extension cords
•Contact and Trigger indicators for fast troubleshoong of hand tool and weld cable maintenance
issues
•Thermal and Voltage protecon indicators to protect the unit from damage due to overheang or
poor input power
•Increased airow for improved eciency and duty cycle
•Rigid internal construcon minimizes the possibility of components coming loose during rough
handling or operaon
•Hand tool has been ergonomically designed to reduce operator fague for increased welding
eciency
•Hand tool has an adjustable internal spring to apply the correct spring pressure for every welding
applicaon
•Hand tool can be congured for B collets, CI (Collet Inserts), Euro collets, or standard tapered
chucks
SPECIFICATIONS AND FEATURES
3

PRODUCT COMPONENTS
Touchscreen Display
Capacitor
Control Board
SCR
Top Panel
Top Open View
Resistor
4

PRODUCT COMPONENTS
Stud Gun Control Cable Connecon
Stud Gun Weld Cable Connecon
Ground Cable Connecon
ON/OFF Switch
10A Fuse
Power Cord Socket
Front Panel View
Side Panel View
5

SCREEN OPERATION
Trigger Indicator
Stud Presets
Metric Stud Mode
Contact Indicator
Stud Preset Screen
Voltage Preset Screen
Charge Indicator
Welding Voltage
Stud Counter
Voltage
Adjustment
Adjustment
Voltage
Presets
Mode Selecon
Voltage
Mode Selecon
6

SCREEN OPERATION
Stud Counter Screen
Reseng the Stud Counter
Stud Counter Reset
•While on the stud counter screen, press the RESET tab located at the boom of the screen.
•The screen will then prompt the user for a conrmaon to clear the stud counter.
•To cancel the reseng of the stud counter, simply press NO on the screen.
•To conrm the reseng of the stud counter, simply press YES on the screen.
Stud Count
7

Screen Status Indicators
SCREEN OPERATION
Status Indicator
Status
Indicator Descripon Soluon
OVERTEMP Unit Has Exceeded
Temperature Threshold
Unit needs to cool down before more welds can be
made. Please allow the unit to cool down and clear
the overtemp warning.
UNDER
VOLTAGE
Insucient Input
Power
Unit has detected insucient supply power. Connect
the unit to a more stable power supply.
DC LIMIT ON Duty Cycle Limiter
Acvated
Protects capacitor from overheang by liming the
user to a maximum average duty cycle. This protec-
on only acvates when the set point of the welder
is above 85V. Below 85V there is no limitaon to the
duty cycle of the unit.
ERR: CHRG TIME Max Charge Time
Exceeded
Unit has taken too long to charge and there may be an
issue with the capacitor. With unit powered down en-
sure that all connectors and connecons are ght.
ERR: OUTPUT Capacitor Short
Detecon
Capacitor is not charging properly and the outputs
may be shorted. Check the unit for damage as well as
the SCR for a short circuit.
8