Truweld TWP-1 User manual

OPERATION MANUAL

TWE Pin Welder

Model TWP-1

TRU‐WELDEQUIPMENTCOMPANY

6400N.HONEYTOWNROAD

SMITHVILLE,OHIO44677

(330)669‐2773

CONTENTS

SectionDescriptionPages

1ProductFeatures3

3ExternalFeatures5‐6

4Safety7‐9

5SetupandWelding10‐14

6TestingWeldSettings15

7InspectingTheWeld16

8TWP‐1Views17

2Specifications4



Model:TWP‐1

TheTWP‐1incorporatesthelatestsolidstatetechnologyintoacompact

andrugged,portableCDPinWelder.Thissystemhasthecapacitytoweld

pins(includingcuppedheadpins)upto10‐gaugeandCDStudsupto#10.



FEATURES

• DigitalDCvoltagereadout(allowsformoreaccurateandrepeatable

weldsettings).

• Coolingfanforincreasedefficiency.

• Dial‐downDCvoltagesetting(noneedtoturnofftheunitwhenreset‐

tingtoalowervoltage).

• Only15ampcircuitrequirement(unitfused@15amps).

• poweroutput@lowerDCvoltagerequirements.

• Terminalconnectionsonthecapacitorareover5/8”indiameterfora

goodseatoftheterminalbussbarstoincreasereliability.

• Theterminalconnectionsonthecapacitorhave1/4‐28socketsetscrews

insertedintoeachone.Thesocketsetscrewisusedtomaketheconnec‐

tiontothebussbar.Thiseliminatesdamagingthethreadsinthealumi‐

numconnectorsofthecapacitor,ensuringasolidconnection.

• Rigidinternalconstructionconnectingtheentireinternalunittothe

frontandrearpanelsminimizestheopportunityofthecomponents

cominglooseduringhandlingoroperations.

• TheTWE‐PinWelderismountedinaruggedoutercaseforgreaterdura‐

bility,texture,andappearance.

• TheTWE‐PinWelderweighsinatabout11poundsforeaseofcarrying.



PRODUCT FEATURES



PRODUCT SPECS

SPECSTWE‐PINWELDER

SIZE105/8”x911/16”x67/8”

270mmx246mmx174mm

WEIGHT10.6lbs.

WELDRANGE

WeldPins‐Upto10gauge

CDStuds‐Upto#10

DUTYCYCLE16‐20pinsperminute

PRIMARYPOWER110VAC@50/60Hz15Ampcircuitor220

VAC@50/60Hz7.5Ampcircuit

CHARGEVOLTAGE35‐110VDC

OperationalandSafetyFeatures

• LEDVoltageMeter

• SafetyShutdown

• CoolingFan

• Front‐PanelInformationalLED’s

• Dial‐Downweldvoltagecontrol



FRONTPANEL



TOPOPENVIEW



EXTERNAL FEATURES

LEDDisplay

VoltageSelector

Weld‐ReadyIndicator

Capacitor

SIDEVIEWS



EXTERNAL FEATURES

StudGunControlCableCon‐

nection

StudGunWeldCableCon‐

nection

GroundCableConnection

ON/OFFSwitch

CoolingFan

15ampCircuitBreaker



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

CONNECTINGTHEWELDINGLEADS

Connectthestudgunweldcableintothegunterminalsocket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.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.







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.



ConnecttheGroundCableintothegroundterminalsocketonthesideoftheunit.

SET-UP AND WELDING

StudGunWeldCableConnection

GroundCableConnection

StudGunControlCableConnection

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