Tru-Weld TWE - SC1900 Operation Manual Download Page 1 | Manualshive

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TRU

‐

WELD

EQUIPMENT

COMPANY

6400

N.

Honeytown

Road

Smithville,

Ohio

44677

(330)

725

‐

7744

Phone

(330)

669

‐

2473

Fax

[email protected]

http://truweldstudwelding.com

Operations Manual

The

SC1900

is

a

fully

integrated

stud

welding

system

with

two

digital

con

‐

trols

for

time

and

current.

The

system

was

designed

to

be

a

perfect

fit

for

shop

use,

excelling

at

small

‐

to

medium

‐

sized

diameter

studs,

all

in

a

com

‐

pact,

affordable

package.

TWE - SC1900

Stud Welding System

Version

1.4

2/13/2012

1
2
3
...
»

Summary of Contents for TWE - SC1900

Page 1: ...ldstudwelding com Operations Manual The SC1900 is a fully integrated stud welding system with two digital con trols for time and current The system was designed to be a perfect fit for shop use excell...

Page 2: ...ding 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 design...

Page 3: ...on Ground Cable Connections 12 6 6 SC1900 Setup and Installation Control Cable Connections 13 7 0 SC1900 Operations Stud Gun Setup 7 1 Stud Gun Setup Initial Steps 14 7 2 Stud Gun Setup Lift Adjustmen...

Page 4: ...Our long standing relationship with our customers and suppliers is our key to contin ued success and growth If we can be of any further assistance to you and your company please do not Product Inform...

Page 5: ...designed and built with operator safety in mind but safety begins with you Every effort has been made to protect the trained operator from injury Please become familiar with the information in this ma...

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: ...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 secu...

Page 8: ...reset for every job On Demand Fan that cycles on and off when needed Weld Range 1 4 to 7 8 Consistent welding regardless of stud diameter Duty Cycle 1 4 thru 3 8 1 2 5 8 3 4 7 8 Unlimited 22 to 24 per...

Page 9: ...ing 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 in stallation Selecting a Location The...

Page 10: ...our requirements These settings should be checked to see if they are properly positioned for the voltage being used Cross the terminals on the Jumper Block with the jumper Figure 1 and tighten down th...

Page 11: ...h the Power Inlet Hole in the top left corner on the backside of the welder Connect the power leads Black White Red to the L1 L2 and L3 connectors as shown in Fig ure 1 Firmly tighten screws that hold...

Page 12: ...tion located in the front of the welder lift access panel Tighten ground cable to welder and secure other end to work surface using the Ground Cable Clamp see Figure 2 Access Panel Ground connection F...

Page 13: ...lug to welder Plug Control Cable plug into port on bottom front of welder lift access panel The Control Cable has a male 4 pole connector on one end that plugs into the port Figure 1 Front of SC1900 A...

Page 14: ...h the stud to be welded After all of the proper accessories have been mounted on the stud gun place the stud in the chuck and begin the alignment of the accessories Make certain that a sufficient amou...

Page 15: ...nging in diameter through 3 4 this adjustment should be suitable For larger diameter studs and select applications the lift should be adjusted to approximately 1 8 Adjusting the lift Remove the back c...

Page 16: ...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 damp ener Rotating the dampener cover counter clockwise...

Page 17: ...the stud gun Make sure welder is set up properly to begin the welding process Place the selected stud into the chuck and attach the ferrule to the ferrule grip Place stud onto surface to be welded an...

Page 18: ...indicating that there is a good connection SC1900 Diagnostic Lights On the Control Panel located below the digital display is a row of diagnostic lights for the welder OUTPUT When the stud gun is trig...

Page 19: ...er clockwise to the correct setting on the digital display Use the Fine Coarse Switch for setting the appropriate time or current this will toggle be tween 10 s or 100 s of amps and 10th s and 100th s...

Page 20: ...g total of the number of welds since the counter was last reset To view the job counter set the Fine Coarse Switch to the Fine position Each weld will be recorded on the Current digital display If the...

Page 21: ...ring 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 i...

Page 22: ...essories so they are centered and adjust legs so that 3 16 to 1 4 of the stud pro trudes beyond the ferrule Make sure work surface is relatively clean so impurities do not affect weld Test the welds a...

Page 23: ...s a bumpy or jagged collar around the base of the weld stud This normally occurs when the weld time is set too high Porous Weld Collar This usually occurs from the oxidation of the weld pool resulting...

Page 24: ...on control panel responds 4 Check to see if weld tool is wired according to one of the three diagrams in Chart A see page 25 5 Locate Touch Trigger Control Board 16002 Chart B Check and note the opera...

Page 25: ...connections in cluding grounds 3 Test the power loop by making welds on a test piece us ing only the starter cable set 4 Test 3 phase power to control contactor 5 Check taps if applicable on main tra...

Page 26: ...Equipment Digital Series Welders will accept any one of these configurations without changing any wiring in the machine When making your own tool extensions 16 4 cable is recommended NOTE Make sure t...

Page 27: ...Active 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...

Page 28: ...ameter Part Number Description Part Number 7 5 16 Diam L 03107 Thru Deck Foot Assembly B 0021 9 5 16 Diam L 03109 Foot Only B 0021 1 14 5 16 Diam L 03114 Extension Bar B 0021 2 18 5 16 Diam L 03118 Sc...

Page 29: ...29 TRU WELD Equipment Company 6400 N Honeytown Road Smithville Ohio 44677 330 725 7744 Phone 330 669 2473 Fax TWE tfpcorp com http truweldstudwelding com...

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