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Operations Manual

TW5700

Stud Welding System

Stud Welding

TRU

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WELD

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Summary of Contents for TW5700

Page 1: ...Operations Manual TW5700 Stud Welding System Stud Welding TRU WELD...

Page 2: ...10 Stud Gun Setup Lift Adjustment 11 Stud Gun Setup Free Travel Adjustment and Weld Preparation 12 Cable Connection Ground Cable Connections 13 Cable Connection Weld Cable Connections 14 Machine Oper...

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: ...long standing relationship with our customers and suppliers is our key to continued success and growth If we can be of any further assistance to you and your company please do not hesitate to contact...

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: ...to 10 per minute 4 to 5 per minute 3 to 4 per minute Dimensions Height Width Length Weight 22 559mm 25 635mm 30 762mm 445 Lbs 202kg Input Voltages 230 460 575 VAC 3 Phase 60Hz Fusing Requirements slow...

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: ...g should be checked to see if they are properly positioned for the voltage being used Remove the TW5700 top cover Cross the terminals on the jumper block with the jumper and tighten the hold down nuts...

Page 11: ...ts Primary Power Cable and Ground Connection Remove the top cover of the TW5700 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: ...ot 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 stud...

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: ...ipped with one ground cable connection located beneath the access panel on the front of the machine Tighten the ground cable to the bracket and secure the heavy duty C clamp to the work surface Ground...

Page 16: ...le connection on the front of the welder behind the access panel Tighten the weld cable lug to the weld cable bracket labeled weld cable Plug the male control cable connector to the female panel mount...

Page 17: ...d connection TW5700 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 sett...

Page 18: ...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 19: ...me Setting 1 Verify the supervisor lock is off 2 Set the FINE COARSE switch to the desired position 3 Press and hold the TIME button 4 Turn the dial to adjust the setting 5 Release the TIME button Adj...

Page 20: ...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 21: ...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 22: ...35 5 16 0 300 550 312 7 93 3 8 0 350 600 375 9 52 7 16 0 420 700 437 11 11 1 2 0 500 900 500 12 70 5 8 0 670 1200 625 15 87 3 4 0 830 1600 750 19 04 7 8 1 000 1800 875 22 22 1 1 200 2100 1 000 25 40...

Page 23: ...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 24: ...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 25: ...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 26: ...sed 3 Check to see if trigger LED on control panel responds 4 Check to see if weld tool is wired accordingly 5 Locate Touch Trigger control board 16002 check and note the operation of the driver LED s...

Page 27: ...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 28: ...LED 3 L3 15Vdc LR6 PA L2 WORK LR3 GUN C A GREEN Pos 15V Supply D1 Pilot Arc Output Stud On Work Indicator GC FUSE Indicator Channel A Selected LED 4 L4 15Vdc LR4 COIL L3 TRIG LG2 GUN P B GREEN Neg 15...

Page 29: ...021P or B 0021A 5 16 x 9 L 03109 Foot Only B 0021 1P or B 0021 1A 5 16 x 14 L 03114 Extension Bar B 0021 2 5 16 x 18 L 03118 Screws B 0021 3 3 8 x 7 L 03707 Thru Deck Ferrule Holder Part Number 3 8 x...

Page 30: ...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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