Truweld TWP-2 User manual

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
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
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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
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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

6
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
15ampCircuitBreaker

7
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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.
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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.

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.
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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.

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.
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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.

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.
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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.
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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

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.
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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

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.
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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.

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.
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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.
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SET-UP AND WELDING