Truweld TWP-1 User manual

OPERATION MANUAL
TWE Pin Welder
Model TWP-1
TRU‐WELDEQUIPMENTCOMPANY
6400N.HONEYTOWNROAD
SMITHVILLE,OHIO44677
(330)669‐2773

CONTENTS
SectionDescriptionPages
1ProductFeatures3
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
8TWP‐1Views17
2Specifications4

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Model:TWP‐1
TheTWP‐1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.
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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of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11poundsforeaseofcarrying.
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PRODUCT FEATURES

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PRODUCT SPECS
SPECSTWE‐PINWELDER
SIZE105/8”x911/16”x67/8”
270mmx246mmx174mm
WEIGHT10.6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

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FRONTPANEL
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TOPOPENVIEW
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EXTERNAL FEATURES
LEDDisplay
VoltageSelector
Weld‐ReadyIndicator
Capacitor

SIDEVIEWS
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EXTERNAL FEATURES
StudGunControlCableCon‐
nection
StudGunWeldCableCon‐
nection
GroundCableConnection
ON/OFFSwitch
CoolingFan
15ampCircuitBreaker

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PROTECTYOURSELFANDOTHERS!
Readthesafetynoticesbeforeusingwelder.
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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.
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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.
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SAFETY

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FIRE
Duringwelding,smallparticlesofhotmetalcanbeexpelled.Ensurethatnocombus‐
tiblematerialsareneartheweldingarea.
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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.
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SAFETY
FIRE HAZARD
FROM SPARKS

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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.
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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.
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SAFETY
AUTHORIZED
PERSONNEL ONLY

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.
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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.
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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

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.
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SET-UP AND WELDING

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.
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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.
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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

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.
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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

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.
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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.
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VOLTAGESELECTION
• Selectingtherequiredweldvoltageisachievedbyturningtheselectorknob.The
voltagerangeisfrom35VDCto130VDC.
• 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.
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SET-UP AND WELDING
ON/OFFSWITCH
15ampCircuitBreaker
VoltageSelectorLEDDisplay

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.
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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.
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TESTING WELD SETTINGS

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.
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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.
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SET-UP AND WELDING

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TWP-1 VIEWS