Stud welding products StudPro 2500 User manual

OPERATION MANUAL

MODELS

TWE-250

TWE-321

TWE-375

TRU‐WELDEQUIPMENTCOMPANY

6400N.HONEYTOWNROAD

SMITHVILLE,OHIO44677

(330)669‐2773

MODELS

StudPro 2500

StudPro 3125

StudPro 3750

Downey, CA

9459 Washburn Rd.

Downey, CA 90242

Phone- 800.252.1919

Fax- 562.862.3022

Hayward, CA

2391 American Ave.

Hayward, CA 94545

Phone- 510.782.7883

Fax- 510.782.7918

Renton, WA

927 Thomas Ave. SW

Renton, WA 98057

Phone- 425.656.9787

Fax- 425.656.9786

Phoenix, AZ

3535 East Wier Ave., Ste. #4

Phoenix, AZ 85040

Phone- 602.305.9350

Fax- 602.305.4890

Toll free customer support: 1.800.252.1919

CONTENTS

SectionDescriptionPages

1Introduction3

2ExternalFeatures4‐5

3Safety6‐8

4SetupandWelding9‐15

5TestingWeldSettings16

6InspectingTheWeld17

7CDStudGunViews18

8CDStudGunExplodedView19

9CDStudGunPartsList20

10CDControllerExplodedView21

11CDControllerPartsList22

1 Introducon 3

2 External Features 4-5

3 Safety 6-8

4 SetupandWelding 9-15

5 TesngWeldSengs 16-19

6 TypesofFractures 20

7 ArcBlowEect 21

8 CDStudGunExplodedView 22

9 InternalComponents 23-25

10 CDAccessoreis 26-29

11 TorqueBendingTest 30-31

12 CDGunSetUp’s 32-33

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.



Theequipmentconsistsofacontrolunit,aweldinghandgun,andallnecessaryinter‐

connectingcables.



THEPROCESS

CapacitorDischarge(CD)studweldingisaformofweldinginwhichtheenergyre‐

quiredfortheweldingprocessisderivedfromabankofchargedcapacitors.This

storedenergyisdischargedatthebaseofthespeciallydesignedCDstudanditfuses

thestudtothebasematerial.Thetimeoftheweldisdeterminedinsuchashortdu‐

rationthatnoburnthroughmarkingismadeonthefinishsideofthematerial.



CONTACT

IncontactCDwelding,thestudisplacedunderspringpressureonthematerialtobe

welded.Whenthecapacitorsaredischarged,thespecialtipoftheCDstudmeltsand

thespringpressureforcesthestudtofusewiththebasematerial.



GAP

IngapCDwelding,thestudisplacedontothematerialtobewelded.Asthestudgun

isengaged,thestudliftsfromthebasematerialandthenreturnstothepointofcon‐

tactatthetimeofthedischargeofthecapacitors.Asthecapacitorsdischarge,melt‐

ingthetipoftheweldstud,thepressurecreatedbythemovementofthestudtothe

basematerialbythestudgunfusesthestudtothebasematerial.

INTRODUCTION



FRONT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.WeldingGroundCableConnector(+)

5.StudGunControlConnector

6.WeldingStudGunCableConnector(‐)



EXTERNAL FEATURES

1

4

2

56

3

654

REARPANEL

1.On/OffSwitch

2.FuseHolder(10amp)

3.ACPowerCord

4.ManufacturerModelNumberandSerialNumberPlate



WARNING!

Thisunitoperatesfroma110VAC60Hertz@10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.



EXTERNAL FEATURES

ON/OFFSwitch

15AmpFuse

PowerSupplyFan

ACCord

ON/OFF Switch

15Amp Fuse

Power Supply Fan

AC Cord



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



FIRE

Duringwelding,smallparticlesofhotmetalcanbeexpelled.Ensurethatnocombus‐

tiblematerialsareneartheweldingarea.



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



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.



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

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.



ON/OFFSwitch



Fuse



PowerCord(110VAC)



CONNECTINGTHEWELDINGLEADS

Connecttheweldinggroundcableintothe(+)terminalmountsocketonthefront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.



GroundCableSocket

SET-UP AND WELDING

Ground Cable Socket

ON/OFF Switch

Fuse

Power Cord (110 VAC)

CONNECTINGTHEWELDINGLEADS

Connecttheweldingstudgunpowercableintothe(‐)terminalpanelmountsocket

(designatedbythegunsymbol)onthefront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.





WeldingGunPowerConnector



WeldingGunControlCableConnector



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.

SET-UP AND WELDING

Welding Gun Control Cable Connector

Welding Gun Power Connector

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