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Related Manuals for Tru-Weld TW4400
Summary of Contents for Tru-Weld TW4400
- Page 1 TRU-WELD Stud Welding TW4400 Stud Welding System Operations Manual...
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Page 2: Table Of Contents
Safety Precautions - Electric Shock and Arc Rays Safety Precautions - Welding Sparks and EMF’s TW4400 Product Specifications TW4400 Setup and Installation - Initial Steps TW4400 Setup and Installation - Power Diagrams TW4400 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
The TW4400 is a fully integrated 1000A stud welding system for ferrule-shielded and gas-shielded drawn arc stud welding. The TW4400 contains digital controls for weld time, weld current, and gas purge time. The system was designed to be a perfect fit for shop use, welding up to 5/8” diameter threaded studs. -
Page 5: Safety Precautions - Symbols And Fumes
Do not install, operate, or repair the TW4400 welding equipment without reading this manual and all safety precautions stated within! The TW4400 was designed and built with operator safety in mind. Every effort has been made to protect the trained operator from injury. Familiarization with the information in this manual is to minimize the risk of shock or injury. -
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: Tw4400 Product Specifications
TW4400 Product Specifications Weld Range 14ga to 5/8” Consistent welding regardless of stud diameter Duty Cycle 14ga thru 1/4” Unlimited 3/8” 7 to 8 per minute 1/2” 4 to 5 per minute 5/8” 2 to 3 per minute Dimensions Height 12.6”... -
Page 9: Tw4400 Setup And Installation - Initial Steps
The welding power source is designed to be operated from three-phase, 60Hertz, AC power supply. Consult the local electrical utility supplier if there are any questions on the electrical system at the present installation site. The TW4400 should be operated from a separate, fused or circuit-breaker protected circuit. -
Page 10: Tw4400 Setup And Installation - Power Diagrams
Power Connection Diagrams Electrical Input Requirements The TW4400 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: Tw4400 Setup And Installation - Primary Power
Do not touch electrically hot parts Primary Power Cable and Ground Connection Remove the top cover of the TW4400 Route the primary power cable through the power inlet hole in the top left corner on the backside of the welder with enough slack to reach the terminal... -
Page 12: Stud Gun Setup - Initial Steps
Stud Gun Setup TWE19000 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 And Weld Connections
C-clamp to the work surface Ground connection Weld Cable Connections The TW4400 has one weld and control cable connection on the front of the welder labeled gun and control Tighten the weld cable to the machine by rotating the connector clockwise ... -
Page 16: Machine Operation - Powering On And Control Panel
TW4400 Operation TW4400 Power Switch/Power On The power switch for the TW4400 is located on the right front of the welder’s control panel. Off position is vertical 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 17: Machine Operation - Menu Selection
TW4400 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 18: Machine Operation - Time And Current Settings
TW4400 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. -
Page 19: Machine Operation - Preset Menu
TW4400 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. -
Page 20: Machine Operation - Stud Counters
TW4400 Operation Weld Counter and Weld Counter Reset The TW4400 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 21: Suggested Time And Current Settings
TW4400 Suggested Weld Settings Suggested Settings (Full Base and Treaded Diameter Studs) -
Page 22: 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 23: Welding Hints And Suggestions
TW4400 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 24: Weld Inspection - Visual Inspection
TW4400 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 25: Tw4400 Troubleshooting
TW4400 Troubleshooting Problem Possible Cause Unit will not turn on No power 1. Test 3 phase power to control contactor 2. Check voltage selection plug near control transformer 3. Make these checks before contacting a TWE Rep Fan does not run when unit is Fan Failure 1. -
Page 26: Tw4400 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 27 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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