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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

 

 

Do not leave an energized machine unattended

 

 

Never work in wet clothing, gloves or footwear

 

 

Insulate yourself from work and ground using dry insulation, make certain the insulation is 
large enough to cover your full area of physical contact with work and ground

 

 

Inspect all system components, protective equipment, cables, connectors and gas lines prior 
to operating equipment, never use cables that are longer than necessary

 

 

When testing a live unit, use the one

-

hand method, do not put both hands inside of the unit, 

keep one hand free

 

 

Disconnect input power conductors from de

-

energized supply line before moving a welding 

power source

 

 

Always be sure the work cable makes a good electrical connection with the metal being   
welded, the connection should be as close as possible to the area being welded

 

 

Turn OFF welding power source before servicing unless the procedure specifically requires an 
energized unit

 

 

Never touch the energized stud or gun before discharging the stud to ground

 

 

Never use the power source to provide heat for thawing frozen pipes

 

 

 

ARC RAYS and EYE PROTECTION

 

 

Arc rays can injure eyes and burn skin. 

 

Arc flashes are painful.

 

 

 

Use a shield with the proper filter and cover plates to protect eyes from sparks and the rays of 
the arc when welding or while observing open arc welding

 

 

Use protective clothing specifically intended for work with welding equipment, it should be 
made of durable flame

-

resistant material to provide ample protection from the arc rays

 

 

Protect other nearby workers with suitable, non

-

flammable screening

 

 

Caution other workers not to watch the arc nor expose themselves to the arc rays or to hot 
spatter or metal

 

Stud Welding Safety Precautions

 

4

 

Summary of Contents for TW4300

Page 1: ...Operations Manual TW4300 Stud Welding System Stud Welding TRU WELD...

Page 2: ...imary Power 9 Stud Gun Setup Initial Steps 10 Stud Gun Setup Lift Adjustment 11 Stud Gun Setup Free Travel Adjustment and Weld Preparation 12 Cable Connection Ground Cable and Weld Connections 13 Mach...

Page 3: ...continued to be used after a defect had been found Equipment which was damaged in any way Truweld Equipment will never be liable for consequential damages loss or expense occurring directly or indirec...

Page 4: ...growth If we can be of any further assistance to you and your company please do not hesitate to contact us Product Information The TW4300 is a fully integrated 800A stud welding system for ferrule shi...

Page 5: ...d Every effort has been made to protect the trained operator from injury Familiarization with the information in this manual is to minimize the risk of shock or injury STUD WELDING CAN BE HAZARDOUS AL...

Page 6: ...ne before moving a welding power source Always be sure the work cable makes a good electrical connection with the metal being welded the connection should be as close as possible to the area being wel...

Page 7: ...hem with electrical tape when possible Never coil the work cable around any part of the body Do not stand between the work cables Connect the work cable to the work piece as close as possible to the a...

Page 8: ...d 5 to 6 per minute 2 to 3 per minute Dimensions Height Width Length Weight 12 6 320mm 11 280mm 22 4 570mm 106 Lbs 48kg Input Voltages 230 460 VAC 3 Phase 60Hz Fusing Requirements slow acting 230 50 A...

Page 9: ...nt is not being installed immediately store it in a clean dry well ventilated area until installation Selecting a Location The location of the power source should be carefully selected to ensure satis...

Page 10: ...es depending on the supplied voltage The jumper setting should be checked to see if they are properly positioned for the voltage being used Remove the TW4300 top cover Plug in the appropriate voltage...

Page 11: ...ts Primary Power Cable and Ground Connection Remove the top cover of the TW4300 Route the primary power cable through the power inlet hole in the top left corner on the backside of the welder with eno...

Page 12: ...foot piece and slide the legs through the front cap nuts After the accessories have been mounted to the stud gun place a stud into the chuck and begin the alignment of the accessories Fully seat a stu...

Page 13: ...ng applications and studs ranging up to 3 4 in diameter Larger diameter studs and select applications should have an 1 8 lift setting Adjusting the lift Remove the back cap of the stud gun Loosen the...

Page 14: ...n to weld and control cable extension Actuate the stud gun without placing it on the surface to be welded to assure that the connection through the control cable is correct to complete the circuit Con...

Page 15: ...ting the connector clockwise and then secure the C clamp to the work surface Weld Cable Connections The TW4300 has one weld and control cable connection on the front of the welder labeled gun and cont...

Page 16: ...connection TW4300 Control Panel Brightness Switch LED brightness can be set to indoor or outdoor brightness levels Time Button Used to adjust time settings Current Button Used to adjust current setti...

Page 17: ...er and a lifetime unit counter Menu Selection 1 Verify supervisor lock is off 2 To chose a menu depress and hold down the adjustment dial 3 Turn adjustment dial clockwise or counter clockwise to cycle...

Page 18: ...the desired position 3 Press and hold the TIME button 4 Turn the dial to adjust the setting 5 Release the TIME button Adjusting the Current Setting 1 Verify the supervisor lock is off 2 Set the FINE C...

Page 19: ...to the Preset Menu 3 Navigate to the desired custom preset 4 Press and hold the dial in until the menu switches back to the Weld Settings Menu Selecting a Factory Preset 1 Navigate to the Preset Menu...

Page 20: ...Weld Counter Non resettable Is a running total of every time an arc is drawn on the machine This is programmed from the factory and can not be reset Resetting The Job Counter 1 Navigate to the Job Cou...

Page 21: ...Full Base and Treaded Diameter Studs DIA INCH TIME SEC AMPS DC DIA DEC DIA MM 1 4 0 150 0 220 260 350 250 6 35 5 16 0 220 0 360 320 420 312 7 93 3 8 0 260 0 420 450 600 375 9 52 7 16 0 310 0 500 530 7...

Page 22: ...ges the weld stud down into the molten pool of metal in the base material The cycle is completed in less than a second and the resulting weld bond develops the full strength of the fastener in the wel...

Page 23: ...ered and adjust legs so that 3 16 to 1 4 of the stud protrudes beyond the ferrule Make sure work surface is relatively clean so impurities do not affect weld Remove all coatings from weld areas Test t...

Page 24: ...when the weld current is set too low Irregular Weld Irregular welds normally occur when the weld time is set too high and the fillet will be bumpy or jagged in appearance Porous Weld Collar A porous w...

Page 25: ...the driver LED s and report the status Unit turns on no coil test no lift from gun coil trigger is good Bad connection or faulty equipment 1 Test control cable by plugging weld tool directly into unit...

Page 26: ...L weld current carry leads and connections including grounds 3 Test the power loop by making welds on a test piece using only the starter cable set 4 Test 3 phase power to control contactor 5 Check ta...

Page 27: ...TRU WELD Stud Welding Equipment Division 6400 N Honeytown Road Smithville Ohio 44677 330 725 7744 Phone 330 669 2473 Fax TWE tfpcorp com http truweldstudwelding com Version 1 02 01 2019...

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