Truweld TW6802 User manual

Operations Manual
TW6802
Heavy-Duty Stud Welding System
Stud Welding
TRU-WELD

Table of Contents
Descripon Page
Warranty Informaon 1
Company Prole and Product Informaon 2
Safety Precauons - Symbols and Fumes 3
Safety Precauons - Electric Shock and Arc Rays 4
Safety Precauons - Welding Sparks and EMF’s 5
TW6802 Product Specicaons 6
TW6802 Setup and Installaon - Inial Steps 7
TW6802 Setup and Installaon - Power Diagrams 8
TW6802 Setup and Installaon - Primary Power 9
Stud Gun Setup - Inial Steps 10
Stud Gun Setup - Li Adjustment 11
Stud Gun Setup - Free Travel Adjustment and Weld Preparaon 12
Cable Connecon - Ground Cable Connecons 13
Cable Connecon - Weld Cable Connecons 14
Machine Operaon - Powering On and Control Panel 15
Machine Operaon - Menu Selecon 16
Machine Operaon - Time and Current Sengs 17
Machine Operaon - Preset Menu 18
Machine Operaon - Stud Counters 19
Suggested Time and Current Sengs 20
Welding - Step by Step Process 21
Welding Hints and Suggesons 22
Weld Inspecon - Visual Inspecon 23
TW6802 Troubleshoong 24
TW6802 Troubleshoong 25
TW6802 Troubleshoong 26
Parts and Accessories 27

TRU-WELD EQUIPMENT LIMITED WARRANTY
All goods produced by TRU-WELD shall be warranted against defects including workmanship and components. No other
warran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. At the opon of
TRU-WELD the locaon of where the warranty evaluaon and repairs are made will be determined. All warranty claim
items returned to TRU-WELD will be at the customer’s expense. At the opon of TRU-WELD the defect will either be
repaired or replaced. Noce must be provided to TRU-WELD 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 was connued to be used aer a defect had been found
• Equipment which was damaged in any way
Truweld 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 ● TW5500 Power Supply
● TWE250CP Power Supply ● SC950 Power Supply ● SC2402 Power Supply ● TW5600 Power Supply
● TWE321 Power Supply ● SC1400Power Supply ● SC2420 Power Supply ● TW5700 Power Supply
● TWE375 Power Supply ● SC1450 Power Supply ● SC3400 Power Supply ● TW6800 Power Supply
● TW-i250 Power Supply ● SC1600 Power Supply ● SC3402 Power Supply ● TW6802 Power Supply
● TW-i250CP Power Supply ● SC1650 Power Supply ● SC3422 Power Supply ● TW6900 Power Supply
● TW-i321 Power Supply ● SC1900 Power Supply ● TW4300 Power Supply ● TW6902 Power Supply
● TW-i375 Power Supply ● SC1950 Power Supply ● TW4400 Power Supply ● TW6950 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 CD stud gun ● TWE18500 MD arc stud gun
● TWEHDG CD stud gun ● TWE19000 LD arc stud gun
Warranty Information
1

Company and Product Information
Company Prole
TRU-WELD Stud Welding has been manufacturing weld studs since 1959 and high-quality stud welding
equipment since 1970. TRU-WELD is located in Medina, Ohio and has product and equipment
distributors throughout the United States and Canada.
Our Mission
Our experienced Management and Sta is commied to provide the utmost in quality and service in
every step of our producon, while remaining compeve in the marketplace. It is our goal to meet
our customer's needs more eecvely than our competors through a process of connuous quality
improvement. Our long-standing relaonship with our customers' and suppliers' is our key to
connued success and growth. If we can be of any further assistance to you and your company,
please do not hesitate to contact us.
Product Informaon
The TW6802 is a fully integrated dual-gun stud welding system with two digital controls for me and
current. The system is designed to meet the most challenging stud welding jobs.
Features:
 Enhanced duty cycle for producon requirements and powerful output for even the largest
diameter jobs
 Factory presets and user customizable presets
 Improved weld control
 PRO-TECH’D technology protects the gun circuitry
Complete system Includes:
 (1) TWE6802 power supply
 (2) TWE17000 HD stud gun
 (2) 50’ of 4/0 weld and control cable
 (2) 25’ of 4/0 ground cable assembly
2

Do not install, operate, or repair this equipment without carefully reading the manual and
observing all of the safety precauons menoned.
Safety Symbols
Every eort has been made to protect trained operators from injury or unnecessary risk. Certain
symbols are used throughout this manual to call aenon to safety-related informaon and in-
strucon. The safety symbols in this manual have these meanings:
This symbol indicates dangerous situaons. When this symbol is used within this
manual, death or serious bodily harm is possible or probable if the corresponding
preventave measures are not taken. Operators must take cauon in the method and
manner of handling or using the machine when this symbol is displayed.
Safety Precauons
Do not install, operate, or repair the TW6802 welding equipment without reading this manual and
all safety precauons stated within!
The TW6802 was designed and built with operator safety in mind. Every eort has been made to
protect the trained operator from injury. Familiarizaon with the informaon in this manual is to
minimize the risk of shock or injury.
STUD WELDING CAN BE HAZARDOUS. ALWAYS PROTECT YOURSELF AND OTHERS
FROM POSSIBLE INJURY OR DEATH. KEEP CHILDREN AWAY.
Operators who have a pacemaker should consult with their physician before operang stud weld-
ing equipment.
FUMES and OXYGEN DEPLETION
 Only weld in areas where adequate venlaon of weld gases is possible and where there is no
re, smoke, or explosion hazards
 When working in a conned space always have trained support personnel nearby
 Welding fumes and gases can displace air and lower the oxygen level causing injury or death, be
sure the breathing air is safe
 Do not weld in locaons near degreasing, cleaning, or spraying operaons, the heat and rays of
the arc can react with vapors resulng in highly toxic or irritang gases
 Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, coangs and
metals containing these elements can generate toxic fumes when heated to welding
temperature
Stud Welding Safety Precautions
3

ELECTRIC SHOCK
Electric shock can injure or kill!
Precauonary measures must be taken to provide maximum protecon against
electrical shock
 Do not touch live or energized electrical parts or store metallic objects near power
 Ground the work or metal to be welded to a good electrical (earth) ground
 Do not leave an energized machine unaended
 Never work in wet clothing, gloves or footwear
 Insulate yourself from work and ground using dry insulaon, make certain the insulaon is
large enough to cover your full area of physical contact with work and ground
 Inspect all system components, protecve equipment, cables, connectors and gas lines prior
to operang equipment, never use cables that are longer than necessary
 When tesng a live unit, use the one-hand method, do not put both hands inside of the unit,
keep one hand free
 Disconnect input power conductors from de-energized supply line before moving a welding
power source
 Always be sure the work cable makes a good electrical connecon with the metal being
welded, the connecon should be as close as possible to the area being welded
 Turn OFF welding power source before servicing unless the procedure specically requires an
energized unit
 Never touch the energized stud or gun before discharging the stud to ground
 Never use the power source to provide heat for thawing frozen pipes
ARC RAYS and EYE PROTECTION
Arc rays can injure eyes and burn skin.
Arc ashes are painful.
 Use a shield with the proper lter and cover plates to protect eyes from sparks and the rays of
the arc when welding or while observing open arc welding
 Use protecve clothing specically intended for work with welding equipment, it should be
made of durable ame-resistant material to provide ample protecon from the arc rays
 Protect other nearby workers with suitable, non-ammable screening
 Cauon other workers not to watch the arc nor expose themselves to the arc rays or to hot
spaer or metal
Stud Welding Safety Precautions
4

Stud Welding Safety Precautions
WELDING SPARKS
Heat from ames and arcs can start res. Hot slag or sparks can also cause res and
explosions.
Remove all combusble materials from the work area or cover these materials with a protecve
non-ammable tarp. Combusble materials include wood, fabrics, sawdust, liquid and gas fuels,
solvents, paints and coangs, paper, etc.
Hot sparks or hot metal can fall through cracks or crevices in oors or wall openings and cause a
hidden smoldering re. Make certain that such openings are protected from hot sparks and metal.
ELECTRIC and MAGNETIC FIELDS
Electric current owing through any conductor causes localized Electro-Magnec Fields (EMF).
Welding and cung current creates EMF around welding cables and welding machines.
 Operators having pacemakers should consult their physician before welding, EMF may
interfere with some pacemakers
 Exposure to EMF may have other health eects, which are unknown
 Operators should use the following procedures to minimize exposure to EMF
 Route the work cables together, secure them with electrical tape when possible
 Never coil the work cable around any part of the body
 Do not stand between the work cables
 Connect the work cable to the work piece as close as possible to the area being welded
 Keep welding power source and cables as far away from your body as possible
 Electromagnec elds can irrevocable erase magnec data carriers (computer memory, credit
cards, security ID cards, etc.)
 Electromagnec elds may magneze and damage watches or similar digital devices
PROTECT YOURSELF and OTHERS
Some welding, cung, and gouging processes are noisy and require ear protecon.
The arc, like the sun, emits ultraviolet (UV) and other radiaon and may injure skin and
eyes. Hot metal can cause burns. Training in the proper use of welding processes and
equipment is essenal to prevent accidents.
 Wear ameproof type gloves, heavy long-sleeve shirt, cu less trousers, and a welding helmet
or cap for hair protecon, to protect against arc rays and hot sparks or hot metal. A ame-
proof apron may also be desirable as protecon against radiated heat and sparks.
 Hot sparks or metal can lodge in rolled up sleeves, trouser cus, or pockets. Sleeves and col-
lars should be kept buoned, and open pockets eliminated from the front of clothing.
5

Weld Range
1/4” to 1” Consistent welding regardless of stud diameter.
Duty Cycle
1/4” thru 5/8”
3/4”
7/8”
1”
Unlimited
18 to 24 per minute
12 to 14 per minute
6 to 8 per minute
Dimensions
Height
Width
Length
Weight
28” (736.6mm)
29” (711.2mm)
36” (914.4mm)
695 Lbs.
Input Voltages
230 / 460 / 575 VAC 3 Phase 60Hz
Fusing Requirements
(slow acng)
230 / 200 Amps
460 / 100 Amps
575 / 90 Amps
TW6802 Product Specifications
** Specicaons are subject to change without prior nocaon
6

TW6802 Setup and Installation
Inial Steps
Only qualied personnel should perform this installaon.
This secon provides detailed instrucons for the proper installaon of the TW6802. It is
recommended that these instrucons be followed carefully to allow for the best possible oper-
ang environment.
Handling and Unpacking the Welder
Immediately upon receipt of the welder, inspect the shipment for any damage and nofy the
carrier of such damage before accepng delivery. Inspect welder for damage which may have
occurred in transit. Aer removing the components from the shipping container(s), check the
container for any loose parts. Remove all packing materials. Visually check all air passages of
power source for any packing materials that may obstruct airow through the welder. If the
equipment is not being installed immediately, store it in a clean, dry, well-venlated area unl
installaon.
Selecng a Locaon
The locaon of the power source should be carefully selected to ensure sasfactory and
dependable service. Choose a locaon relavely close to a properly fused source of electrical
power. Use care against toppling over if the machine is placed on a lted surface or plane. It is
important that the machine be located in an open area where air can circulate freely through the
front and rear openings. If space is at a premium, leave at least 1 foot (300 mm) of clearance
between the rear of the power source and wall or other obstrucon.
Electrical Input Requirement
The welding power source is designed to be operated from three-phase, 60Hertz, AC power
supply. Consult the local electrical ulity supplier if there are any quesons on the electrical
system at the present installaon site. The TW6802 should be operated from a separate, fused or
circuit-breaker protected circuit.
7

TW6802 Setup and Installation
Power Connecon Diagrams
Electrical Input Requirements
The TW6802 is equipped with an input voltage jumper block so the unit can be operated with
dierent line voltages depending on the supplied voltage. The jumper seng should be checked
to see if they are properly posioned for the voltage being used.
 Remove the TW6802 top cover
 Cross the terminals on the jumper block with the jumper and ghten the hold down nuts
 Use the schemac below for the jumper seng to suit the line voltage requirements
1234
5
61234
5
61234
5
6
L1 L2 L3
1234
5
61234
5
61234
5
6
L1 L2 L3
460VAC
Jumpers
1234
5
61234
5
61234
5
6
L1 L2 L3
8
575VAC
230VAC

TW6802 Setup and Installation
Preparing the Unit for Primary Power
Only qualied personnel should perform this installaon.
 Turn the input power o at the disconnect switch or fuse box before working on the welder
 Do not touch electrically hot parts
Primary Power Cable and Ground Connecon
 Remove the top cover of the TW6802
 Route the primary power cable through the power inlet hole in the top le corner on the
backside of the welder with enough slack to reach the terminal block
 Connect the ground wire to the frame of the welder as shown below
 Connect the power leads (black, white, red) to the L1, L2, and L3 connectors on the terminal
block, as shown below
Power
Connecons
Ground
Connecon
9

Stud Gun Setup
TWE17000 Gun Setup
Each stud welding applicaon requires that the stud gun be set up properly for the correct stud
and ferrule arrangement.
 Select the correct style and size of chuck and aach it to the stud gun
 Select the appropriate length leg assembly, foot piece, and ferrule grip
 Secure ferrule grip to the foot piece
 Tighten leg screws and washers to the foot piece and slide the legs through the front cap
nuts
Aer the accessories have been mounted to the stud gun place a stud into the chuck and begin
the alignment of the accessories.
 Fully seat a stud into the chuck so that the stud is held rmly
 Insert a ferrule into the ferrule grip
 Move the leg, foot and ferrule assembly so that the stud protrudes beyond the ferrule
 1/8” sck out for studs 1/2" and smaller in diameter
 3/16” sck out for studs 5/8” through 7/8” in diameter
 1/4” sck out for studs 1” to 1-1/4” in diameter
 Posion the ferrule grip assembly so that the stud moves freely through the ferrule when li is
simulated
10

Stud Gun Setup
Li
Set the li when all of the accessories and stud have been properly set on the stud gun and prior to
welding. Plug the stud gun control connector directly into the stud welder (do not aach the weld
cable). Turn on the stud welder and actuate the trigger of the stud gun with the stud and ferrule in
place. Note the retracon of the sha of the stud gun, this is designated as the li.
The li seng should be approximately 3/32” for general welding applicaons and studs ranging up
to 3/4” in diameter. Larger diameter studs and select applicaons should have an 1/8” li seng.
Adjusng the li:
 Remove the back cap of the stud gun
 Loosen the two socket set screws around the periphery of the li adjustment screw
 To increase li rotate the li adjustment screw counter clockwise and to decrease li rotate
clockwise
 With each turn check the li by actuang the stud gun unl the desired li is achieved
 Tighten the socket set screws to hold the li adjustment screw in place to secure the selected
seng
 Replace the back cap of the stud gun
Rear coil yoke
Set screw
Li adjusng screw
Gun body
11

Stud Gun Setup
Free Travel Adjustment
This adjustment can be used to control the force with which the stud is plunged into the molten
weld pool by moving the engagement point of when the sha of the stud gun engages the damp-
ener. Rotang the dampener cover counter clockwise increases the amount of free travel.
Dampener cover
12
Aaching the stud gun to start welding
 Select the gun, control cable, and weld cable that is recommended for the specic type of
welder and job
 Aach stud gun to weld and control cable extension
 Actuate the stud gun without placing it on the surface to be welded to assure that the
connecon through the control cable is correct to complete the circuit
 Conrm me and current sengs are correct
 Place the selected stud into the chuck and aach the ferrule to the ferrule grip
 Place stud onto surface to be welded and press stud gun down unl ferrule is ush with the
welding surface
 Trigger the gun and hold in place unl cycle is completed
 Pull gun assembly straight up o of the welded stud
 Do not depress trigger when removing gun from stud
 Remove the ferrule by breaking it o and inspect the weld
 Make proper adjustments if needed

TW6802 Cable Connection
Ground Cable Connecons
 The TW6802 is equipped with two ground cable connecons located beneath the access panel
on the front of the machine
 Tighten the ground cable to the bracket and secure the heavy duty C-clamp to the work
surface
Access panelGround connecons
Ground cable lug
Ground cable C-clamp
13

TW6802 Cable Connection
Weld Cable Connecons
 The TW6802 has two weld and control cable connecons on the front of the welder behind
the access panel
 Tighten the weld cable lug to the weld cable bracket labeled Gun 1
 Plug the male control cable connector to the female panel mount labeled Gun 1
 Repeat these steps for the Gun 2 connecons
Access Panel Weld Cable Connecons
(Dual Gun)
Control Cable Connecons
(Dual Gun)
14

TW6802 Operation
TW6802 Power Switch/Power On
The power switch for the TW6802 is located on the right
front of the welder’s control panel. O posion is ver-
cal with the “O” showing. On posion is horizontal with
the “I” displayed.
When the welder is turned on, the digital display will go
through a self-diagnosc check. This takes approximately
3 to 5 seconds, and then the digital display will show the
last me and current seng. Once the me and current
is displayed, the unit is ready to weld. When connected
to the welder, the stud gun will actuate 3 mes, indi-
cang that there is a good connecon.
TW6802 Control Panel
Brightness Switch — LED brightness can be set to indoor or outdoor brightness levels
Time Buon — Used to adjust me sengs
Current Buon — Used to adjust current sengs
Digital Display — Displays weld sengs, machine presets, or weld counters
Diagnosc LED — Used to determine an issue with weld/control cable or machine
Fine/Coarse Switch — Can be selected to adjust me or current by 10th’s or 100th’s
Menu Opons — Shows which menu the machine is displaying
Adjustment Dial — Used to toggle through menus or adjust the me and current
Supervisor Lock — Locks the machine so changes cannot be made to the weld sengs
Brightness Switch
Adjustment Dial
Current Buon
Digital Display
Time Buon
Fine/Coarse Switch
Supervisor Lock
Menu Opons
Diagnosc LED
15

TW6802 Operation
Menu Selecon
By depressing the adjustment dial and rotang clockwise or counter clockwise a
menu can be chosen. The menus include weld sengs, welding presets, job
counter, and a lifeme unit counter.
Menu Selecon:
1. Verify supervisor lock is o
2. To chose a menu, depress and hold down the adjustment dial
3. Turn adjustment dial clockwise or counter-clockwise to cycle through the
dierent menu opons
4. Stop rotang the dial when the LED for the desired menu is illuminated
5. Release the adjustment dial
Adjustment dial
Supervisor lock
Menu opons
16

TW6802 Operation
Weld Sengs - Time and Current
The me and current controls are located on the front of the welder. The controls
consist of a me buon, current buon, adjustment dial, ne/coarse switch, and a
supervisor lock. The digital display will indicate the sengs chosen during setup.
Adjusng the Time Seng:
1. Verify the supervisor lock is o
2. Set the FINE/COARSE switch to the desired posion
3. Press and hold the TIME buon
4. Turn the dial to adjust the seng
5. Release the TIME buon
Adjusng the Current Seng:
1. Verify the supervisor lock is o
2. Set the FINE/COARSE switch to the desired posion
3. Press and hold the AMPS buon
4. Turn the dial to adjust the seng
5. Release the AMPS buon
Adjustment dial
Current buon
Digital display
Time buon
Fine/Coarse switch
Supervisor lock
17

TW6802 Operation
Preset Menu
The full range of studs the machine is capable of welding is preloaded onto the unit
for fast and easy access. Any combinaon of me and current can also be saved to a
programmable preset locaon.
Selecng Custom Presets:
1. Navigate to the Preset Menu
2. Rotate the dial counter-clockwise to the desired preset
3. Press and release dial
Saving Custom Presets:
1. Set the weld sengs to the sengs to be saved
2. Navigate to the Preset Menu
3. Navigate to the desired custom preset
4. Press and hold the dial in unl the menu switches back to the Weld Sengs
Menu
Selecng a Factory Preset:
1. Navigate to the Preset Menu
2. Rotate the dial clockwise to the desired stud diameter
3. Press and release the dial
Exing back to the Weld Sengs Menu (all available opons):
1. Navigate to the Weld Sengs Menu using the dial method listed previously
2. Turn the dial to the end of the custom preset opons, press and release the dial
3. Turn the dial to the end of the factory preset opons, press and release the dial
4. Press and release the AMPS or TIME adjustment buons
18