TRU-WELD TW6900 Stud Welding System Instruction Manual

TW6900 Stud Welding System

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Specifications

• Model: TW6900
• Power Supply: 3000A
• Controls: Two digital controls for time and current
• Designed for: Challenging stud welding jobs including through
  deck

Product Information

The TW6900 is a heavy-duty stud welding system designed by
TRU-WELD. It is a fully integrated system with a 3000A power supply
and single-gun operation. The system features two digital controls
for precise time and current settings, making it suitable for
various stud welding applications, including challenging tasks like
through deck welding.

Features:

• Enhanced duty cycle for production requirements
• Powerful output for large diameter jobs
• Factory presets and user-customizable presets
• Improved weld control
• PRO-TECH’D technology to protect gun circuitry

Complete System Includes:

• 1 TW6900 power supply
• 1 TWE17000 HD stud gun
• 1 50′ of 4/0 weld and control cable
• 1 25′ of 4/0 ground cable assembly

Product Usage Instructions

Stud Welding Safety Precautions

Before using the TW6900 stud welding system, it is crucial to
follow these safety precautions:

• Read the manual carefully before installation, operation, or
  repair.

• Observe all safety precautions mentioned in the manual.

Safety Symbols

In the manual, safety symbols are used to highlight important
safety-related information and instructions. Here are the meanings
of some common safety symbols:

• Warning symbol: Indicates a potential hazard
  that may result in serious injury or death if not avoided.

• Caution symbol: Alerts you to a potential
  hazard or unsafe practice that could result in minor or moderate
  injury if not avoided.

FAQ

What is the warranty period for the TW6900 stud welding

system?

The TW6900 system comes with a two-year warranty period from the
date of purchase for the power supply and stud gun included in the
package.

Can I customize the welding presets on the TW6900 system?

Yes, the TW6900 system allows users to customize welding presets
according to their specific requirements in addition to the factory
presets provided.

How should I handle cables and connectors for the TW6900

system?

Please note that all cables, cable sets, and connectors are not
covered under warranty. Handle them with care to prevent damage and
ensure proper functioning of the system.

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TRU-WELD
Stud Welding

TW6900
Heavy-Duty Stud Welding System
Operations Manual

Tru-Fit Products/Tru-Weld 460 Lake Road Medina, Ohio 44256

800-321-5588 Phone truweld@tfpcorp.com
www.tfpcorp.com
www.truweldstudwelding.com

Table of Contents
Description Warranty Information Company Profile and Product Information Safety Precautions – Symbols and Fumes Safety Precautions – Electric Shock and Arc Rays Safety Precautions – Welding Sparks and EMF’s TW6900 Product Specifications TW6900 Setup and Installation – Initial Steps TW6900 Setup and Installation – Power Diagrams TW6900 Setup and Installation – Primary Power Stud Gun Setup – Initial Steps Stud Gun Setup – Lift Adjustment Stud Gun Setup – Free Travel Adjustment and Weld Preparation Cable Connection – Ground Cable Connections Cable Connection – Weld Cable Connections Machine Operation – Powering On and Control Panel Machine Operation – Menu Selection Machine Operation – Time and Current Settings Machine Operation – Preset Menu Machine Operation – Stud Counters Suggested Time and Current Settings Welding – Step by Step Process Welding Hints and Suggestions Weld Inspection – Visual Inspection TW6900 Troubleshooting TW6900 Troubleshooting TW6900 Troubleshooting Parts and Accessories

Page 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 24 25 26 27

Warranty Information

TRU-WELD EQUIPMENT LIMITED WARRANTY
All goods produced by TRU-WELD shall be warranted against defects including workmanship and components. No other warranties whether expressed, verbal, or implied will apply. Warranties only apply to the original equipment purchaser.

Warranty claims will be limited to either repair or replacement of the defective materials by TRU-WELD. At the option of TRU-WELD the location of where the warranty evaluation and repairs are made will be determined. All warranty claim items returned to TRU-WELD will be at the customer’s expense. At the option of TRU-WELD the defect will either be repaired or replaced. Notice must be provided to TRU-WELD of a warranty defect within 30 days that the defect or failure is incurred. Warranties 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 modified · 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 was 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 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 TW5500 Power Supply

TWE250CP Power Supply

SC950 Power Supply

SC2402 Power Supply TW5600 Power Supply

TWE321 Power Supply

SC1400Power Supply

SC2420 Power Supply

TW5700 Power Supply

TWE375 Power Supply

SC1450 Power Supply SC3400 Power Supply TW6800 Power Supply

TW-i250 Power Supply

SC1600 Power Supply SC3402 Power Supply TW6802 Power Supply

TW-i250CP Power Supply

SC1650 Power Supply SC3422 Power Supply TW6900 Power Supply

TW-i321 Power Supply

SC1900 Power Supply TW4300 Power Supply TW6902 Power Supply

TW-i375 Power Supply

SC1950 Power Supply TW4400 Power Supply TW6950 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 CD stud gun

TWE18500 MD arc stud gun

TWEHDG CD stud gun

TWE19000 LD arc stud gun

1

Company and Product Information
Company Profile TRU-WELD Stud Welding has been manufacturing weld studs since 1959 and high-quality stud welding equipment since 1970. TRU-WELD is located in Medina, Ohio and has product and equipment distributors throughout the United States and Canada.
Our Mission Our experienced Management and Staff is committed to provide the utmost in quality and service in every step of our production, while remaining competitive in the marketplace. It is our goal to meet our customer’s needs more effectively than our competitors through a process of continuous quality improvement. Our 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 us.
Product Information The TW6900 is a fully integrated 3000A single-gun stud welding system with two digital controls for time and current. The system is designed to meet the most challenging stud welding jobs including through deck.
Features: Enhanced duty cycle for production requirements and powerful output for even the largest
diameter jobs Factory presets and user customizable presets Improved weld control PRO-TECH’D technology protects the gun circuitry
Complete system Includes: (1) TW6900 power supply (1) TWE17000 HD stud gun (1) 50′ of 4/0 weld and control cable (1) 25′ of 4/0 ground cable assembly
2

Stud Welding Safety Precautions
Do not install, operate, or repair this equipment without carefully reading the manual and observing all of the safety precautions mentioned.
Safety Symbols
Every effort has been made to protect trained operators from injury or unnecessary risk. Certain symbols are used throughout this manual to call attention to safety-related information and instruction. The safety symbols in this manual have these meanings:
This symbol indicates dangerous situations. When this symbol is used within this manual, death or serious bodily harm is possible or probable if the corresponding preventative measures are not taken. Operators must take caution in the method and manner of handling or using the machine when this symbol is displayed.
Safety Precautions
Do not install, operate, or repair the TW6900 welding equipment without reading this manual and all safety precautions stated within!
The TW6900 was designed and built with operator safety in mind. 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. ALWAYS PROTECT YOURSELF AND OTHERS FROM POSSIBLE INJURY OR DEATH. KEEP CHILDREN AWAY.
Operators who have a pacemaker should consult with their physician before operating stud welding equipment.
FUMES and OXYGEN DEPLETION
Only weld in areas where adequate ventilation of weld gases is possible and where there is no fire, smoke, or explosion hazards
When working in a confined space always have trained support personnel nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death, be
sure the breathing air is safe Do not weld in locations near degreasing, cleaning, or spraying operations, the heat and rays of
the arc can react with vapors resulting in highly toxic or irritating gases Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, coatings and
metals containing these elements can generate toxic fumes when heated to welding temperature
3

Stud Welding Safety Precautions
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
4

Stud Welding Safety Precautions
WELDING SPARKS
Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions.
Remove all combustible materials from the work area or cover these materials with a protective non-flammable tarp. Combustible materials include wood, fabrics, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire. Make certain that such openings are protected from hot sparks and metal.
ELECTRIC and MAGNETIC FIELDS
Electric current flowing through any conductor causes localized Electro- Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines.
Operators having pacemakers should consult their physician before welding, EMF may interfere with some pacemakers
Exposure to EMF may have other health effects, which are unknown Operators should use the following procedures to minimize exposure to EMF Route the work cables together, secure them 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 area being welded Keep welding power source and cables as far away from your body as possible Electromagnetic fields can irrevocable erase magnetic data carriers (computer memory, credit
cards, security ID cards, etc.) Electromagnetic fields may magnetize and damage watches or similar digital devices
PROTECT YOURSELF and OTHERS
Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and may injure skin and eyes. Hot metal can cause burns. Training in the proper use of welding processes and equipment is essential to prevent accidents.
Wear flameproof type gloves, heavy long-sleeve shirt, cuff less trousers, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks.
Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.
5

TW6900 Product Specifications

Weld Range Duty Cycle
Dimensions Input Voltages

1/4″ to 1-1/4″

Consistent welding regardless of stud diameter.

1/4″ thru 5/8″ 3/4″ 7/8″ 1″ 1-1/4″

Unlimited 18 to 24 per minute 12 to 14 per minute 6 to 8 per minute 4 to 5 per minute

Height Width Length Weight

28″ (736.6mm) 29″ (711.2mm) 36″ (914.4mm) 760 Lbs. (345kg)

230 / 460 / 575 VAC 3 Phase 60Hz

Fusing Requirements (slow acting)

230 / 200 Amps 460 / 100 Amps 575 / 90 Amps

** Specifications are subject to change without prior notification 6

TW6900 Setup and Installation
Initial Steps
Only qualified personnel should perform this installation.
This section provides detailed instructions for the proper installation of the TW6900. It is recommended that these instructions be followed carefully to allow for the best possible operating environment.
Handling and Unpacking the Welder
Immediately upon receipt of the welder, inspect the shipment for any damage and notify the carrier of such damage before accepting delivery. Inspect welder for damage which may have occurred in transit. After removing the components from the shipping container(s), check the container for any loose parts. Remove all packing materials. Visually check all air passages of power source for any packing materials that may obstruct airflow through the welder. If the equipment 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 satisfactory and dependable service. Choose a location relatively close to a properly fused source of electrical power. Use care against toppling over if the machine is placed on a tilted surface or plane. It is important that the machine be located in an open area where air can circulate freely through the front and rear openings. If space is at a premium, leave at least 1 foot (300 mm) of clearance between the rear of the power source and wall or other obstruction.
Electrical Input Requirement
The welding power source is designed to be operated from three-phase, 60Hertz, AC power supply. Consult the local electrical utility supplier if there are any questions on the electrical system at the present installation site. The TW6900 should be operated from a separate, fused or circuit-breaker protected circuit.
7

TW6900 Setup and Installation
Power Connection Diagrams
Electrical Input Requirements
The TW6900 is equipped with an input voltage jumper block so the unit can be operated with different line voltages 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 TW6900 top cover Cross the terminals on the jumper block with the jumper and tighten the hold down nuts Use the schematic below for the jumper setting to suit the line voltage requirements
Jumpers

230VAC

L1

1 2 3 4

6

5

460VAC

L1

1 2 3 4

6

5

575VAC

L1

1 2 3 4

6

5

L2

1 2 3 4

6

5

L2

1 2 3 4

6

5

L2

1 2 3 4

6

5

8

L3

1 2 3 4

6

5

L3

1 2 3 4

6

5

L3

1 2 3 4

6

5

TW6900 Setup and Installation
Preparing the Unit for Primary Power Only qualified personnel should perform this installation.
Turn the input power off at the disconnect switch or fuse box before working on the welder Do not touch electrically hot parts
Primary Power Cable and Ground Connection Remove the top cover of the TW6900 Route the primary power cable through the power inlet hole in the top left corner on the
backside of the welder with enough slack to reach the terminal block Connect the ground wire to the frame of the welder as shown below Connect the power leads (black, white, red) to the L1, L2, and L3 connectors on the terminal
block, as shown below

Power Connections

Ground Connection

9

Stud Gun Setup
TWE17000 Gun Setup
Each stud welding application requires that the stud gun be set up properly for the correct stud and ferrule arrangement.
Select the correct style and size of chuck and attach it to the stud gun Select the appropriate length leg assembly, foot piece, and ferrule grip Secure ferrule grip to the foot piece Tighten leg screws and washers to the 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 stud into the chuck so that the stud is held firmly Insert a ferrule into the ferrule grip Move the leg, foot and ferrule assembly so that the stud protrudes beyond the ferrule
1/8″ stick out for studs 1/2″ and smaller in diameter 3/16″ stick out for studs 5/8″ through 7/8″ in diameter 1/4″ stick out for studs 1″ to 1-1/4″ in diameter Position the ferrule grip assembly so that the stud moves freely through the ferrule when lift is simulated
10

Stud Gun Setup
Lift Set the lift when all of the accessories and stud have been properly set on the stud gun and prior to welding. Plug the stud gun control connector directly into the stud welder (do not attach the weld cable). Turn on the stud welder and actuate the trigger of the stud gun with the stud and ferrule in place. Note the retraction of the shaft of the stud gun, this is designated as the lift.
The lift setting should be approximately 3/32″ for general welding 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 two socket set screws around the periphery of the lift adjustment screw To increase lift rotate the lift adjustment screw counter clockwise and to decrease lift rotate
clockwise With each turn check the lift by actuating the stud gun until the desired lift is achieved Tighten the socket set screws to hold the lift adjustment screw in place to secure the selected
setting Replace the back cap of the stud gun

Rear coil yoke

Set screw
Lift adjusting screw Gun body

11

Stud Gun Setup
Free Travel Adjustment This adjustment can be used to control the force with which the stud is plunged into the molten weld pool by moving the engagement point of when the shaft of the stud gun engages the dampener. Rotating the dampener cover counter clockwise increases the amount of free travel.
Dampener cover
Attaching the stud gun to start welding Select the gun, control cable, and weld cable that is recommended for the specific type of welder and job Attach stud gun 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 Confirm time and current settings are correct Place the selected stud into the chuck and attach the ferrule to the ferrule grip Place stud onto surface to be welded and press stud gun down until ferrule is flush with the welding surface Trigger the gun and hold in place until cycle is completed Pull gun assembly straight up off of the welded stud Do not depress trigger when removing gun from stud Remove the ferrule by breaking it off and inspect the weld Make proper adjustments if needed
12

TW6900 Cable Connection
Ground Cable Connections
The TW6900 is equipped 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 connections

Access panel Ground cable lug

Ground cable C-clamp
13

TW6900 Cable Connection
Weld Cable Connections
The TW6900 has one weld and control cable 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 labeled control cable

Access Panel

Control Cable Connection

Weld Cable Connections

14

TW6900 Operation
TW6900 Power Switch/Power On
The power switch for the TW6900 is located on the right front of the welder’s control panel. Off position is vertical with the “O” showing. On position is horizontal with the “I” displayed.
When the welder is turned on, the digital display will go through a self- diagnostic check. This takes approximately 3 to 5 seconds, and then the digital display will show the last time and current setting. Once the time and current is displayed, the unit is ready to weld. When connected to the welder, the stud gun will actuate 3 times, indicating that there is a good connection.
TW6900 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 settings Digital Display — Displays weld settings, machine presets, or weld counters Diagnostic LED — Used to determine an issue with weld/control cable or machine Fine/Coarse Switch — Can be selected to adjust time or current by 10th’s or 100th’s Menu Options — Shows which menu the machine is displaying Adjustment Dial — Used to toggle through menus or adjust the time and current Supervisor Lock — Locks the machine so changes cannot be made to the weld settings

Brightness Switch Time Button Current Button Digital Display Diagnostic LED

Fine/Coarse Switch Menu Options
Adjustment Dial Supervisor Lock
15

TW6900 Operation
Menu Selection
By depressing the adjustment dial and rotating clockwise or counter clockwise a menu can be chosen. The menus include weld settings, welding presets, job counter, and a lifetime unit counter.
Menu options Adjustment dial Supervisor lock
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 through the
different menu options 4. Stop rotating the dial when the LED for the desired menu is illuminated 5. Release the adjustment dial
16

TW6900 Operation
Weld Settings – Time and Current
The time and current controls are located on the front of the welder. The controls consist of a time button, current button, adjustment dial, fine/coarse switch, and a supervisor lock. The digital display will indicate the settings chosen during setup.

Time button Current button Digital display

Fine/Coarse switch Adjustment dial Supervisor lock

Adjusting the Time 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
Adjusting the Current Setting:
1. Verify the supervisor lock is off 2. Set the FINE/COARSE switch to the desired position 3. Press and hold the AMPS button 4. Turn the dial to adjust the setting 5. Release the AMPS button
17

TW6900 Operation
Preset Menu
The full range of studs the machine is capable of welding is preloaded onto the unit for fast and easy access. Any combination of time and current can also be saved to a programmable preset location.
Selecting Custom Presets:
1. Navigate to the Preset Menu 2. Rotate the dial counter-clockwise to the desired preset 3. Press and release dial
Saving Custom Presets:
1. Set the weld settings to the settings to be saved 2. Navigate 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 2. Rotate the dial clockwise to the desired stud diameter 3. Press and release the dial
Exiting back to the Weld Settings Menu (all available options):
1. Navigate to the Weld Settings Menu using the dial method listed previously 2. Turn the dial to the end of the custom preset options, press and release the dial 3. Turn the dial to the end of the factory preset options, press and release the dial 4. Press and release the AMPS or TIME adjustment buttons
18

TW6900 Operation
Weld Counter and Weld Counter Reset
The TW6900 is equipped with two different counters to display the number of times the unit has drawn an arc. Job Counter (Resettable) – Is a running total of the number of welds since the counter was last reset. This counter can easily be reset from the job counter menu. Unit 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 Counter Menu 2. Press and hold the dial in until the counter changes to 0 Viewing Unit Counter: 1. Navigate to the Unit Counter Menu Exiting Unit/Job Counter: – To exit the counter menu navigate to the weld settings menu using the dial method or press and release the AMPS or TIME adjustment buttons.
Job counter will display here
19

TW6900 Suggested Weld Settings
Suggested Settings (Full Base Diameter Studs)
20

DIA INCH 1/4 5/16 3/8 7/16 1/2 5/8 3/4 7/8 1 1-1/4
3/4 7/8

TIME SEC

AMPS DC

DIA DEC

0.200

500

.250

0.300

550

.312

0.350

600

.375

0.420

700

.437

0.500

900

.500

0.670

1200

.625

0.830

1600

.750

1.000

1800

.875

1.200

2100

1.000

1.800

2400

1.250

APPROXIMATE SETTINGS FOR THRU-DECK WELDING

.800 – 1.4

16-1900

.750

1.0 – 1.6

18-2200

.875

DIA MM 6.35 7.93 9.52 11.11 12.70 15.87 19.04 22.22 25.40 31.70
19.04 22.22

TW6900 Welding
Stud Welding – Step by Step
The weld gun is positioned over the base material and the main gun spring is partially compressed. Hold gun perpendicular to work surface and hold ferrule firmly against the surface.
The trigger is pressed and the stud lifts off the base, drawing an arc. The arc melts the end of the weld stud and the base material below. The arc shield (ferrule) concentrates the heat below the weld stud and contains the molten metal within the weld zone. Do not move weld gun during weld.
The main spring plunges 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 weld zone. Allow metal to cool and withdraw gun from the stud, pulling the gun straight up off of the stud.
The weld gun is withdrawn from the weld stud leaving and the ferrule. The ferrule is broken away and discarded. Visually inspect weld.

Note – when determining finished length required for the particular application, keep in mind the reduction in length (burn-off) from stud welding operations. TRU-WELD stud lengths are always given before weld.

Diameter of Stud 1/4″ thru 1/2″ 5/8″ thru 7/8″ 1″ and over

Reduction in Length 1/8″ 3/16″ 1/4″

21

TW6900 Welding Hints and Suggestions
Stud Welding
· Keep weld studs and ferrules clean and dry · Set the time for the appropriate weld base diameter (see chart on page 19) · Set the amperage for the appropriate weld base diameter (see chart on page 19) · Make sure the negative polarity is to the weld stud gun and ensure a good, clean ground
connection · Align accessories so they are centered 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 the welds at the beginning of each shift or change in stud size. Bend two studs 30° after
cooling (AWS Bend Test) · Check burn off (1/8″ ­ 3/16″), color (silver-blue and shiny), and weld fillet (360°). · Visually inspect all welds
Thru-Deck Stud Welding
· Keep weld studs and ferrules clean and dry · Never attempt thru-deck welding when the ambient temperature is below 32oF · Deck must be layered flat on supporting members · Deck must be properly grounded, be sure all cable connections are tight and secure · Always use a thru-deck style ferrule · Visually inspect all welds
To ensure satisfactory welds, bend test a minimum of one stud out of every one-hundred, by striking stud with a hammer and bending the stud 15o from its original axis
22

TW6900 Weld Inspection
Visual Weld Inspection and Adjustments – After shooting the stud, break away ferrule and visually inspect the weld.
Good Weld
A good weld will have a smooth and even fillet with a blue-silver tint.
Partial Weld
A partial weld will result in a collar that does not extend around the entire diameter of the stud base. This outcome often occurs 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 weld fillet forms from the oxidation of the weld pool when the weld time is set too long and/or current is set too low.
Weld Collar Off-Center
Off-center weld collars have a thick fillet on one half of the stud base and the stud may be tilted. Typically moving the or not having the gun perpendicular to the base material will result in an off-center collar.
23

TW6900 Troubleshooting

Problem
Unit will not turn on
Fan does not run when unit is turned on Fan runs continuously (does not cycle on/off) Unit turns on, coil boot test is good, no trigger from weld gun
Unit turns on, no coil test, no lift from gun coil, trigger is good
Gun lifts, no weld arc drawn

Possible Cause
No power
This is normal Thermostat circuit Bad connection or faulty equipment
Bad connection or faulty equipment
Bad connection or faulty equipment

Fix
1. Test 3 phase power to control contactor 2. Check taps (if applicable) on main transformer 3. Check voltage selection plug near control transformer 4. Check fuse located on control transformer 5. Look for power available LED on control transformer 6. Make these checks before contacting a TWE Rep
The fan will cycle on when the main bridge has reached nominal operating temperature. Ambient temperature of the weld site should also be taken in consideration.
A fault in the thermostatic circuit will cause the fan to run continuously, call a local TRU-WELD rep. for repairs
1. Test control cable by plugging weld tool directly into unit (4 conductor straight through wiring)
2. Check gun trigger resistance (<100 ohms when closed) 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 and report the status
1. Test control cable by plugging weld tool directly into unit (4 conductor straight through wiring)
2. Check 10 amp fuse on control board box next to breakers 3. Check hand tool coil resistance (12 – 40 ohms) 4. Locate Touch/Trigger Control Board TWE16158-1, check
and note the operation of the driver LED’s and report the status
1. Check connections for ground and weld tool leads 2. Check if contact LED on control panel lights when stud is
touched to work surface (closing circuit) 3. Check the two circuit breakers on the control board box 4. Check to see if you have the sustaining arc (a small blue
arc for the duration of the weld time) 5. Check to see if the stud sparks at the end of the weld
cycle (hot plunge) 6. Locate Touch/Trigger Control Board TWE16158-1, check
and note the operation of the driver LED’s and report the status

24

TW6900 Troubleshooting

Problem
Unit stops welding, overtemp LED is on
Weld output erratic or weak
Weld gun lifts, but does not plunge

Possible Cause
Over heating

Fix
1. If the fan is running, allow unit to cool 2. Slow down welding rate (fewer studs per minute) 3. Any fault in the overtemp thermostat circuit will shut the
system down

Adjustments or settings

1. Check welding hand tool set up, lift, plunge, and accessory adjustments
2. Check ALL 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 taps (if applicable) on main transformer

Gun maintenance

If this happens, it is most likely binding inside of the gun. Perform routine gun maintenance or replace gun if needed

Note – Always turn off power to the welder before working on or testing components within the welder. Contact a TRU-WELD representative for replacement parts and for servicing welding equipment.

25

TW6900 Troubleshooting
Circuit board, control box, fuse, breaker and L.E.D. layout

Board Name LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 FUSE
BREAKER

16000 Digital Control L1- Gate Power 36 Volt Supply
L2- +5Vdc Pos 5V Supply
L3- +15Vdc Pos 15V Supply
L4- -15Vdc Neg 15V Supply
BKR 1,2

16001 Pilot Arc Gun Control GPri – SSR1
Gun Primary GSec – SSR2 Gun Secondary
LR6 – PA D1 Pilot Arc Output
LR4 – COIL BR1,2 Output
LG1 – PAph2 Drive Signal
LR5 – PAph1 Drive Signal LR1 – PAph3 Drive Signal
F2 AGC 10A 250V
¼ X 1¼ Hand Tool 1 Coil

16002 Touch / Trigger
L1 – PWRA – F1,3 Touch Supply L6 – +5VDC Digital Supply L2 – WORK Stud On Work Indicator L3 – TRIG
Trigger Indicator L5 – 2WIRE
Input #2 Supply
L4 – 4WIRE Input #1 Supply
F1,3 1A 125V FST 5 X 20 mm LED 1 PWRA
26

B16001 Gun Control Accessory LG4 – COIL
YZ Output LG3 – GUN-C GLV Signal LR3 – GUN-C GC FUSE Indicator
LG2 – GUN-P GHV Signal
LR2 – GUN-P GP FUSE Indicator
LG1 – ACCESS ACC Signal
LR2 – ACCESS ACC FUSE Indicator F4-6
10A 250V FST 5 X 20 mm
Hand Tool 2 Coil

16060 Dual Gate Drive
Yellow
+15 Vdc Supply RED – Q1 TR1 Active A – GREEN
Channel A Selected
B – GREEN Channel B Selected
RED Q2 TR2 Active

TW6900 Parts and Accessories

Closed Ferrule Grips (1″ Long) Brass

Stud Diameter

Part Number

3/4″

GN-075

7/8″

GN-087

1″

GN-100

Adjustable Chucks

Stud Diameter

Part Number

3/4″

CN-075

7/8″

CN-087

1″ Gun Legs
Diameter & length 5/16″ x 7″ 5/16″ x 9″

CN-100
Part Number L-03107 L-03109

5/16″ x 14″

L-03114

5/16″ x 18″ 3/8″ x 7″ 3/8″ x 9″

L-03118 L-03707 L-03709

3/8″ x 14″ 3/8″ x 18″ 3/8″ x 24″ 3/8″ x 27″ 3/8″ x 32″ 3/8″ x 36″ 3/8″ x 48″
Gun Feet 1/4 – 1/2″ Closed 5/8 – 3/4″ Closed 7/8 – 1″ Closed 1/4 – 1/2″ Split 5/8 – 3/4″ Split
7/8 – 1″ Split

L-03714 L-03718 L-03724 L-03727 L-03732 L-03736 L-03748
B-1N B-2N B-3N B-1C B-2C B-3C

Split Ferrule Grip (1″ Long) Brass

Stud Diameter

Part Number

3/4″

GC-075

7/8″

GC-087

1″

GC-100

Headed Chucks

Stud Diameter

Part Number

5/8 & 3/4″

CH-075

7/8″

CH-087

1″

CH-100

Thru-Deck Accessories

Description

Part Number

Thru-Deck Foot Assembly

B-0021P or B-0021A

Foot Only

B-0021-1P or B-0021-1A

Extension Bar

B-0021-2

Screws Thru-Deck Ferrule Holder
3/4″ WTD/ 7/8″ Flat

B-0021-3 Part Number
B-0060-1

3/4″ Flat

B-0060-2

5/8″ Flat

B-0060-3

1″ Flat

B-0060-4

1/2″ Flat

B-0060-5

Twin Leg Ferrule Foot Plates

Diameter

Part Number

1/4″

QN-025

5/16″

QN-031

3/8″

QN-037

1/2″

QN-050

5/8″

QN-062

3/4″

QN-075

7/8″

QN-087

1″

QN-100

27

TRU-WELD 460 Lake Road Medina, Ohio 44256 800-321-5588 Phone
truweld@tfpcorp.com truweldstudwelding.com

Tru-Fit Products 800-321-5588 460 Lake Rd, Medina, OH 44256

Version 1 05/28/2024

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