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Table of Contents
Troubleshooting
Related Manuals for Tru-Weld TW55000
Summary of Contents for Tru-Weld TW55000
- Page 1 TRU-WELD Stud Welding TW5500 Stud Welding System Operations Manual...
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Page 2: Table Of Contents
Table of Contents Description Page Warranty Information Company Profile and Product Information Safety Precautions - Symbols and Fumes Safety Precautions - Electric Shock and Arc Rays Safety Precautions - Welding Sparks and EMF’s TW5500 Product Specifications TW5500 Setup and Installation - Initial Steps TW5500 Setup and Installation - Power Diagrams TW5500 Setup and Installation - Primary Power Stud Gun Setup - Initial Steps... -
Page 3: Warranty Information
TRU-WELD will be at the customer’s expense. At the option of TRU-WELD the defect will either be repaired or replaced. Notice must be provided to TRU-WELD of a warranty defect within 30 days that the defect or failure is incurred. -
Page 4: Company Profile And Product Information
Company and Product Information Company Profile 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. -
Page 5: Safety Precautions - Symbols And Fumes
Stud Welding Safety Precautions Do not install, operate, or repair this equipment without carefully reading the manual and observing all of the safety precautions mentioned. Safety Symbols Every effort has been made to protect trained operators from injury or unnecessary risk. Certain symbols are used throughout this manual to call attention to safety-related information and in- struction. -
Page 6: Safety Precautions - Electric Shock And Arc Rays
Stud Welding Safety Precautions ELECTRIC SHOCK Electric shock can injure or kill! Precautionary measures must be taken to provide maximum protection 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 ... -
Page 7: Safety Precautions - Welding Sparks And Emf's
Stud Welding Safety Precautions WELDING SPARKS Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Remove all combustible materials from the work area or cover these materials with a protective non-flammable tarp. Combustible materials include wood, fabrics, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc. -
Page 8: Tw5500 Product Specifications
TW5500 Product Specifications Weld Range 1/4” to 5/8” Consistent welding regardless of stud diameter Duty Cycle 1/4” thru 3/8” Unlimited 1/2” 22 to 24 per minute 5/8” 9 to 10 per minute Dimensions Height 22” (559mm) Width 25” (635mm) Length 30”... -
Page 9: Tw5500 Setup And Installation - Initial Steps
TW5500 Setup and Installation Initial Steps Only qualified personnel should perform this installation. This section provides detailed instructions for the proper installation of the TW5500. It is recommended that these instructions be followed carefully to allow for the best possible oper- ating environment. -
Page 10: Tw5500 Setup And Installation - Power Diagrams
TW5500 Setup and Installation Power Connection Diagrams Electrical Input Requirements The TW5500 is equipped with an input voltage jumper block so the unit can be operated with different line voltages depending on the supplied voltage. The jumper setting should be checked to see if they are properly positioned for the voltage being used. -
Page 11: Tw5500 Setup And Installation - Primary Power
TW5500 Setup and Installation Preparing the Unit for Primary Power Only qualified personnel should perform this installation. Turn the input power off at the disconnect switch or fuse box before working on the welder Do not touch electrically hot parts ... -
Page 12: Stud Gun Setup - Initial Steps
Stud Gun Setup TWE18500 Gun Setup Each stud welding application requires that the stud gun be set up properly for the cor- rect stud and ferrule arrangement. Select the correct style and size of chuck and attach it to the stud gun ... -
Page 13: Stud Gun Setup - Lift Adjustment
Stud Gun Setup Lift: Set the lift 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 attach the weld cable). Turn on the stud welder and actuate the trigger of the stud gun with the stud and ferrule in place. -
Page 14: Stud Gun Setup - Free Travel Adjustment And Weld Preparation
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 shaft of the stud gun engages the damp- ener. -
Page 15: Cable Connection - Ground Cable Connections
TW5500 Cable Connection Ground Cable Connections The TW5500 is equipped with one ground cable connection 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 Ground connection Access panel... -
Page 16: Cable Connection - Weld Cable Connections
TW5500 Cable Connection Weld Cable Connections The TW5500 has one weld and control cable connection on the front of the welder behind the access panel Tighten the weld cable lug to the weld cable bracket labeled weld cable ... -
Page 17: Machine Operation - Powering On And Control Panel
TW5500 Operation TW5500 Power Switch/Power On The power switch for the TW5500 is located on the right front of the welder’s control panel. Off position is verti- cal with the “O” showing. On position is horizontal with the “I” displayed. When the welder is turned on, the digital display will go through a self-diagnostic check. -
Page 18: Machine Operation - Menu Selection
TW5500 Operation Menu Selection By depressing the adjustment dial and rotating clockwise or counter clockwise a menu can be chosen. The menus include weld settings, welding presets, job counter, and a lifetime unit counter. Menu options Adjustment dial Supervisor lock Menu Selection: 1. -
Page 19: Machine Operation - Time And Current Settings
TW5500 Operation Weld Settings - Time and Current The time and current controls are located on the front of the welder. The controls consist of a time button, current button, adjustment dial, fine/coarse switch, and a supervisor lock. The digital display will indicate the settings chosen during setup. Fine/Coarse switch Time button Adjustment dial... -
Page 20: Machine Operation - Preset Menu
TW5500 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 combination of time and current can also be saved to a programmable preset location. Selecting Custom Presets 1. -
Page 21: Machine Operation - Stud Counters
TW5500 Operation Weld Counter and Weld Counter Reset The TW5500 is equipped with two different counters to display the number of times the unit has drawn an arc. Job Counter (Resettable) - Is a running total of the number of welds since the coun- ter was last reset. -
Page 22: Suggested Time And Current Settings
TW5500 Suggested Weld Settings Suggested Settings (Full Base Diameter Studs) -
Page 23: Welding - Step By Step Process
Visually inspect weld. Note - when determining finished length required for the particular application, keep in mind the reduction in length (burn-off) from stud welding operations. TRU-WELD stud lengths are always given before weld. -
Page 24: Welding Hints And Suggestions
TW5500 Welding Hints and Suggestions Stud Welding • Keep weld studs and ferrules clean and dry • Set the time for the appropriate weld base diameter (see chart on page 20) • Set the amperage for the appropriate weld base diameter (see chart on page 20) •... -
Page 25: Weld Inspection - Visual Inspection
TW5500 Weld Inspection Visual Weld Inspection and Adjustments - After shooting the stud, break away ferrule and visually inspect the weld. Good Weld A good weld will have a smooth and even fillet with a blue-silver tint. Partial Weld A partial weld will result in a collar that does not extend around the entire diameter of the stud base. -
Page 26: Tw5500 Troubleshooting
Thermostat circuit A fault in the thermostatic circuit will cause the fan to run not cycle on/off) continuously, call a local TRU-WELD rep. for repairs Unit turns on, coil boot test is Bad connection or 1. Test control cable by plugging weld tool directly into unit... -
Page 27: Tw5500 Troubleshooting
Perform routine gun maintenance or replace gun if needed Note - Always turn off power to the welder before working on or testing components within the welder. Contact a TRU-WELD representative for replacement parts and for servicing welding equipment. -
Page 28: Tw5500 Troubleshooting
TW5500 Troubleshooting Circuit board, control box, fuse, breaker and L.E.D. layout Board 16000 16001 16002 B16001 16060 Name Digital Control Pilot Arc Touch / Trigger Gun Control Dual Gate Drive Gun Control Accessory LED 1 L1- Gate Power GPri - SSR1 L1 - PWRA - F1,3 LG4 - COIL Yellow... -
Page 29: Parts And Accessories
TW5500 Parts and Accessories Closed Ferrule Grips (1” Long) Brass Split Ferrule Grip (1” Long) Brass Stud Diameter Part Number Stud Diameter Part Number 3/4” GN-075 3/4” GC-075 7/8” GN-087 7/8” GC-087 1” GN-100 1” GC-100 Adjustable Chucks Headed Chucks Stud Diameter Part Number Stud Diameter... - Page 30 TRU-WELD Stud Welding Equipment Division 6400 N. Honeytown Road Smithville, Ohio 44677 (330) 725-7744 Phone (330) 669-2473 Fax TWE@tfpcorp.com http://truweldstudwelding.com Version 1 02/01/2019...
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