Summary of Contents for Tru-Weld TWE-250 SPC
- Page 1 OPERATION MANUAL MODELS TWE-250 SPC TWE-321 SPC TWE-375 SPC TRU-WELD EQUIPMENT COMPANY 6400 N. HONEYTOWN ROAD SMITHVILLE, OHIO 44677 (330) 725-7744 Version 1.2 12/20/2011...
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Page 2: Table Of Contents
CONTENTS Section Description Pages Introduction External Features Safety Setup and Welding 9-15 Testing Weld Settings Inspecting The Weld CD Stud Gun Exploded View CD Controller Parts List CD Unit Views... -
Page 3: Introduction
INTRODUCTION The complete range of the capacitor discharge equipment is compact, portable stud welding equipment. The units are specifically designed to enable a small diameter range of ferrous and nonferrous weld studs to be welded to light gauge metal materi- als with little or no reverse-side marking. -
Page 4: External Features
EXTERNAL FEATURES SIDE PANEL 1. Weld Voltage Selector - rotate to change to required voltage. 2. Welding Voltage Digital Display - displays selected voltage. 3. LED Lights - Charging (capacitors are being charging to desired voltage), Ready (unit is ready to weld), Reset (indicates an error and unit should be turned off). 4. - Page 5 EXTERNAL FEATURES SIDE PANEL 1.On/Off Switch 2.Fuse Holder (10 amp) 3.AC Power Cord Connector WARNING! This unit operates from a 110 VAC 50/60 Hertz @10 amp circuit or 220 VAC 50/60 Hertz @ 5 amp circuit Do not obstruct the ventilation fan, as this may cause unit to over heat. Do not remove any portion of the unit housing without first disconnecting the unit from the power supply.
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Page 6: Safety
SAFETY 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 anyone other than qualified personnel. Always disconnect the unit from the main power pri- or to removing cover. -
Page 7: Personal Safety
SAFETY FIRE During welding, small particles of hot metal can be expelled. Ensure that no combus- tible materials are near the welding area. FIRE HAZARD FROM SPARKS PERSONAL SAFETY Arc rays can burn your eyes and skin. Wear protective clothing and eye protection when welding. -
Page 8: Authorized Personnel Only
SAFETY 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. AUTHORIZED PERSONNEL ONLY 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... -
Page 9: Setup And Welding
SET-UP AND WELDING POWERING UP THE EQUIPMENT Setup the equipment power supply (Control Unit) and connect to the main power, making certain of the proper voltage requirement of the particular unit. Capacitor Discharge (CD) units generally require 110 VAC @ 60Hz incoming power. Refer to the safety recommendations before plugging this unit in. - Page 10 SET-UP AND WELDING CONNECTING THE WELDING LEADS Connect the welding stud gun power cable into the (-) terminal panel mount socket (designated by the gun symbol) 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.
- Page 11 SET-UP AND WELDING 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. NOTE***Most applications will require only one ground clamp, but certain applica- tions will require an additional dual clamp.
- Page 12 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.
- Page 13 SET-UP AND WELDING SELECTING THE SPRING LOAD The proper spring pre-load setting on the stud gun will vary depending on the select- ed 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.
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Page 14: Ready For Welding
SET-UP AND WELDING 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. -
Page 15: Voltage Selection
SET-UP AND WELDING VOLTAGE SELECTION Selecting the required weld voltage is achieved by turning the selector knob. The voltage range is from 35VDC to 200VDC. The voltage is determined by the diameter of the stud and the base material. Voltage Adjustment Knob Approximate voltage staring points are listed below. -
Page 16: Testing Weld Settings
TESTING WELD SETTINGS 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. -
Page 17: Inspecting The Weld
SET-UP AND WELDING 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. -
Page 18: Cd Stud Gun Exploded View
CD Parts and Accessories CD STUD GUN EXPLODED VIEW... -
Page 19: Cd Controller Parts List
CD Controller Parts List ITEM QUANTITY PART# DESCRIPTION TWE01021 Handle TWE01031 Cover TWE01014 Relay TWE01010 TRIAC TWE01073 Thyristor Plate TWE01030 Cross-Over Link TWE01028 Negative BUSS TWE01002 Thyristor TWE01003 Thyrister Clamp TWE01011 Flyback Diode TWE01004 Main Capacitor TWE01027 Link BUSS Bar TWE01001 PC Board TWE01033... -
Page 20: Cd Unit Views
CD Unit Views...
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