Table of Contents
Troubleshooting
Summary of Contents for Tru-Fit Tru-Weld TW6902
- Page 1 TRU-WELD Stud Welding TW6902 Heavy-Duty Stud Welding System Operations Manual (800) 321-5588 Phone Tru-Fit Products/Tru-Weld truweld@tfpcorp.com 460 Lake Road www.tfpcorp.com Medina, Ohio 44256 www.truweldstudwelding.com...
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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 TW6902 Product Specifications TW6902 Setup and Installation - Initial Steps TW6902 Setup and Installation - Power Diagrams TW6902 Setup and Installation - Primary Power Stud Gun Setup - Initial Steps... -
Page 3: Warranty Information
Warranty Information TRU-WELD EQUIPMENT LIMITED WARRANTY All goods produced by TRU-WELD 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. At the option of TRU-WELD the location of where the warranty evaluation and repairs are made will be determined. -
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. Our Mission Our experienced Management and Staff is committed to provide the utmost in quality and service in every step of our production, while remaining competitive in the marketplace. -
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: Tw6902 Product Specifications
TW6902 Product Specifications Weld Range 1/4” to 1-1/4” Consistent welding regardless of stud diameter. Duty Cycle 1/4” thru 5/8” Unlimited 3/4” 22 to 24 per minute 7/8” 16 to 18 per minute 1” 12 to 14 per minute 1-1/4” 4 to 5 per minute Dimensions Height 28”... -
Page 9: Tw6902 Setup And Installation - Initial Steps
TW6902 Setup and Installation Initial Steps Only qualified personnel should perform this installation. This section provides detailed instructions for the proper installation of the TW6902. It is recommended that these instructions be followed carefully to allow for the best possible oper- ating environment. -
Page 10: Tw6902 Setup And Installation - Power Diagrams
TW6902 Setup and Installation Power Connection Diagrams Electrical Input Requirements The TW6902 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: Tw6902 Setup And Installation - Primary Power
TW6902 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 Primary Power Cable and Ground Connection ... -
Page 12: Stud Gun Setup - Initial Steps
Stud Gun Setup TWE17000 Gun Setup Each stud welding application 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 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). -
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
TW6902 Cable Connection Ground Cable Connections The TW6902 is equipped with two ground cable connections 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 connections Access panel... -
Page 16: Cable Connection - Weld Cable Connections
TW6902 Cable Connection Weld Cable Connections The TW6902 has two weld and control cable connections on the front of the welder behind the access panel Tighten the weld cable lug to the weld cable bracket labeled Gun 1 ... -
Page 17: Machine Operation - Powering On And Control Panel
TW6902 Operation TW6902 Power Switch/Power On The power switch for the TW6902 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
TW6902 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
TW6902 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
TW6902 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
TW6902 Operation Weld Counter and Weld Counter Reset The TW6902 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
TW6902 Suggested Weld Settings Suggested Settings (Full Base Diameter Studs) -
Page 23: Welding - Step By Step Process
TW6902 Welding Stud Welding - Step by Step The weld gun is positioned over the base material and the main gun spring is partially compressed. Hold gun perpendicular to work surface and hold ferrule firmly against the surface. The trigger is pressed and the stud lifts off the base, drawing an arc. The arc melts the end of the weld stud and the base material below. -
Page 24: Welding Hints And Suggestions
TW6902 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 19) • Set the amperage for the appropriate weld base diameter (see chart on page 19) •... -
Page 25: Weld Inspection - Visual Inspection
TW6902 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: Tw6902 Troubleshooting
TW6902 Troubleshooting Problem Possible Cause Unit will not turn on No power 1. Test 3 phase power to control contactor 2. Check taps (if applicable) on main transformer 3. Check voltage selection plug near control transformer 4. Check fuse located on control transformer 5. -
Page 27: Tw6902 Troubleshooting
TW6902 Troubleshooting Problem Possible Cause Unit stops welding, Over heating 1. If the fan is running, allow unit to cool overtemp LED is on 2. Slow down welding rate (fewer studs per minute) 3. Any fault in the overtemp thermostat circuit will shut the system down Weld output erratic or weak Adjustments or... -
Page 28: Tw6902 Troubleshooting
TW6902 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
TW6902 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 460 Lake Road Medina, Ohio 44256 (800) 321-5588 Phone truweld@tfpcorp.com truweldstudwelding.com Tru-Fit Products (800) 321-5588 460 Lake Rd, Medina, OH 44256 Version 1 05/28/2024...
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