Truweld TW-i Series Manuale utente
OPERATOR’S MANUAL
TW-i SERIES
Capacitor Discharge Stud Welder
TRU-WELD EQUIPMENT COMPANY
www.truweldstudwelding.com
(330) 725-7744
MODELS:
TW-i 250
TW-i 250CP
TW-i 321
TW-i 375
CONTENTS
Descripon Pages
Warranty Informaon 1
Safety 2
Specicaons and Features 3
Product Components 4-5
Screen Operaon 6-8
Setup and Welding 9-11
CD Stud Gun Exploded View 12
TRU-WELD EQUIPMENT LIMITED WARRANTY
All goods produced by Tru-Weld Equipment shall be warranted against defects including workmanship and components. No other war-
ranes whether expressed, verbal, or implied will apply. Warranes only apply to the original equipment purchaser.
Warranty claims will be limited to either repair or replacement of the defecve materials by Tru-Weld Equipment. The locaon of
where the warranty evaluaon and repairs are made will be determined at the opon of Tru-Weld Equipment . All warranty claim items
returned to Tru-Weld Equipment will be at the customer’s expense. At the opon of Tru-Weld Equipment the defect will either be re-
paired or replaced. Noce must be provided to Tru-Weld Equipment of a warranty defect within 30 days that the defect or failure is
incurred. Warranes are not transferable.
This warranty does not apply for equipment which is used improperly in any fashion including but not exclusive to the following:
• Equipment which has been modied
• Equipment which has not been installed properly
• Equipment which has been used for purposes other than which it had been designed
• Equipment which has not been properly maintained
• Equipment which has been used aer a defect had been found
• Equipment which has been damaged in any way
Tru-Weld Equipment will never be liable for consequenal damages, loss, or expense occurring directly or indirectly from the use of the
equipment covered in this warranty.
All cables, cable sets, and connectors are not covered under warranty
Two (2) year warranty period from date of purchase
● TWE250 Power Supply ● SC900 Power Supply ● SC2400 Power Supply
● TWE250CP Power Supply ● SC950 Power Supply ● SC2402 Power Supply
● TWE321 Power Supply ● SC1400Power Supply ● SC2420 Power Supply
● TWE375 Power Supply ● SC1450 Power Supply ● SC3400 Power Supply
● TW-i250 Power Supply ● SC1600 Power Supply ● SC3402 Power Supply
● TW-i250CP Power Supply ● SC1650 Power Supply ● SC3422 Power Supply
● TW-i321 Power Supply ● SC1900 Power Supply
● TW-i375 Power Supply ● SC1950 Power Supply
One (1) year warranty period from date of purchase
● TWESPC Power Supply ● TWP-2 Power Supply ● ACE-P100 Power Supply
Ninety (90) day warranty period from date of purchase
● TWEGP CD stud gun ● TWE17000 HD arc stud gun
● TWEG MD CD stud gun ● TWE18500 MD arc stud gun
● TWEHDG HD CD stud gun ● TWE19000 LD arc stud gun
WARRANTY INFORMATION
1
Read the safety noces before operang welder
Electrical
• Due to potenal dangerous electrical input and output the
equipment must be disconnected from all incoming power
when servicing. Do not operate the equipment with the outer
cover removed or with the case open.
• Capacitors store electrical energy, completely discharge before performing any maintenance.
• Do not use uids to clean electrical components as these may penetrate the electrical system
and cause shorts.
• Connecon of the unit into service must be in accordance with the setup procedures as de-
tailed in this manual. Operaon of this equipment must be in accordance with all local, region-
al, and naonal safety codes.
Fire
• During welding, small parcles of hot metal can be expelled. Ensure
that no combusble materials are near the welding area.
Personal Safety
• Arc rays can burn eyes and skin. Wear protecve clothing and eye pro-
tecon when welding.
• Loud noises from welding can damage hearing. Wear earplugs or oth-
er protecve gear, if applicable.
• Fumes and gases expelled during welding can be health hazards. Make sure welding is done in
a well-venlated area.
• Hot metal splaer can cause res and burns. Wear protecve clothing, work in an area free of
combusble materials, and have a re exnguisher nearby.
Maintenance
• All cables must be inspected regularly to ensure that no danger exists from damaged insula-
on or unsafe electrical connecons. Take special note of the cables near the stud gun, this is
where maximum wear occurs.
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 mes.
Installaon
• Select a site which is capable of supporng the weight of the equipment.
• Select a site which is clear from heavy foot trac areas to avoid tripping hazards.
• Select a site that prevents cable damage from equipment and vehicles.
• Do not hang connecng cables over sharp edges or place near heat sources.
SAFETY
FIRE HAZARD
FROM SPARKS
2
SPECIFICATIONS AND FEATURES
TW-i Capacitor Discharge Stud Welder Series
The TW-i series of capacitor discharge stud welders incorporates the latest solid state technology into
a compact, lightweight, and rugged CD stud welder. This full line of equipment is capable of welding
pins, cup head pins, and CD studs ranging from 14-gauge up to 3/8” full-anged stainless steel studs.
Specicaons
Features
• Intuive Touchscreen Interface with preset values for fast, accurate, and repeatable weld sengs
• Set-Point Discharge: Unit discharges directly to a new set point without needing to discharge com-
pletely
• Universal Input Voltage: Plug and play, no need to re-tap the machine for 110V or 220V input volt-
ages
• Low input voltage capability enables operaon with long extension cords
• Contact and Trigger indicators for fast troubleshoong of hand tool and weld cable maintenance
issues
• Thermal and Voltage protecon indicators to protect the unit from damage due to overheang or
poor input power
• Rigid internal construcon minimizes the possibility of components coming loose during rough han-
dling or operaon
• Hand tool has been ergonomically designed to reduce operator fague for increased welding e-
ciency
• Hand tool has an adjustable internal spring to apply the correct spring pressure for every welding
applicaon
• Hand tool can be congured for B collets, CI (Collet Inserts), Euro collets, or standard tapered
chucks
SPECS TW-i 250 TW-i 250CP TW-i 321 TW-i 375
SIZE 14” L, 10.5” W, 11.5” H
356mm x 267mm x 292mm
WEIGHT
(Power Supply Only) 18 lbs. (8.1Kg) 18 lbs. (8.1Kg) 20.8 lbs. (9.4Kg) 23.4 lbs. (10.6Kg)
CAPACITANCE/ENERGY 76,000µF/1520Ws 76,000µF/1520Ws 114,000µF/2280Ws 152,000µF/3040Ws
WELD RANGE 14Ga - 1/4” Stainless
14Ga - 1/4” Stainless
(including cup head pins) 14Ga - 5/16” Stainless 14Ga - 3/8” Stainless
DUTY CYCLE 18 studs per minute
(1/4” sengs)
18 studs per minute
(1/4” sengs)
14 studs per minute
(5/16” sengs)
10 studs per minute
(3/8” sengs)
PRIMARY POWER
(Universal Input) 85-250 VAC, 6.0-2.0A, 50/60Hz
CHARGE VOLTAGE 35-200 VDC
3
* Specicaons are subject to change without prior nocaon
Front View Back View
Components
1. Touch Screen Interface
2. Weld Ground Connector
3. Cup Pin Weld Ground Connector (Model 250CP only, on all other TW-i models this connector is a
secondary Weld Ground Connector)
4. Stud Gun Control Cable Connector
5. Stud Gun Weld Cable Connector
6. ON/OFF Switch
7. 10A Fuse
8. Manufacturer Model Number and Serial Number Plate
9. Power Cord Socket
PRODUCT COMPONENTS
1
4
25
7
3
6
9
8
4
Internal View
Components
1. Venlaon Fan
2. ON/OFF Switch
3. 10A Fuse
4. AC Inline Filter/Power Cord Socket
5. Capacitor Bank
6. Freewheeling Diodes
7. SCR/Clamp
8. Discharge Resistor
9. Control Board
PRODUCT COMPONENTS
4
3
1
2
5
9
876
5
SCREEN OPERATION
Trigger Indicator
Stud Presets
Metric Stud Mode
Contact Indicator
Stud Preset Screen
Voltage Preset Screen
Charge Indicator
Welding Voltage
Stud Counter
Voltage
Adjustment
Adjustment
Voltage
Presets
Mode Selecon
Voltage
Mode Selecon
6
SCREEN OPERATION
Stud Counter Screen
Reseng the Stud Counter
Stud Counter Reset
• While on the stud counter screen, press the RESET tab located at the boom of the screen.
• The screen will then prompt the user for a conrmaon to clear the stud counter.
• To cancel the reseng of the stud counter, simply press NO on the screen.
• To conrm the reseng of the stud counter, simply press YES on the screen.
Stud Count
7
Screen Status Indicators
SCREEN OPERATION
Status Indicator
8
Status
Indicator Descripon Soluon
OVERTEMP Unit Has Exceeded
Temperature Threshold
Unit needs to cool down before more welds can be
made. Please allow the unit to cool down and clear
the overtemp warning.
UNDER
VOLTAGE
Insucient Input
Power
Unit has detected insucient supply power. Connect
the unit to a more stable power supply.
DC LIMIT ON Duty Cycle Limiter
Acvated
Protects capacitor from overheang by liming the
user to a maximum average duty cycle. This protec-
on only acvates when the set point of the welder
is above 85V. Below 85V there is no limitaon to the
duty cycle of the unit.
ERR: CHRG TIME Max Charge Time
Exceeded
Unit has taken too long to charge and there may be an
issue with the capacitor. With unit powered down en-
sure that all connectors and connecons are ght.
ERR: OUTPUT Capacitor Short
Detecon
Capacitor is not charging properly and the outputs
may be shorted. Check the unit for damage as well as
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