background image

3

 

 

Table

 

of

 

Contents

 

Section

 

Description

 

Page

 

1.0

 

Cover

 

1

 

2.0

 

Table

 

of

 

Contents

 

3

 

3.0

 

Company

 

Profile

 

and

 

Product

 

Information

 

4

 

4.0

 

Safety

 

Precautions

 

 

4.1

 

Safety

 

Precautions

 ‐ 

Symbols

 

and

 

Description

 

5

 

4.2

 

Safety

 

Precautions

 ‐ 

Electric

 

Shock

 

6

 

4.3

 

Safety

 

Precautions

 ‐ 

Welding

 

Sparks

  

7

 

5.0

 

Product

 

Specifications

 

8

 

6.0

 

SC1900

 

Setup

 

and

 

Installation

 

 

6.1

 

SC1900

 

Setup

 

and

 

Installation

 ‐ 

Initial

 

Steps

 

9

 

6.2

 

SC1900

 

Setup

 

and

 

Installation

 ‐ 

Power

 

Diagrams

  

10

 

6.3

 

SC1900

 

Setup

 

and

 

Installation

 ‐ 

Primary

 

Power

 

11

 

6.5

 

SC1900

 

Setup

 

and

 

Installation

 ‐ 

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

 

Adjustment

 

15

 

7.3

 

Stud

 

Gun

 

Setup

 ‐ 

Plunge

 

Adjustment

 

16

 

7.4

 

Stud

 

Gun

 

Setup

 ‐ 

Cable

 

Connections

 

17

 

8.0

 

SC1900

 

Operations

 ‐ 

Settings

 

 

8.1

 

SC1900

 

Operations

 ‐ 

Unit

 

Power/Diagnostic

 

Lights

 

18

 

8.2

 

SC1900

 

Operations

 ‐ 

Setting

 

Time

 

and

 

Current

 

19

 

8.3

 

SC1900

 

Operations

 ‐ 

Setting

 

Job

 

Counter

 

20

 

9.0

 

SC1900

 

Operations

 ‐ 

Welding

 

 

9.1

 

Step

 

by

 

Step

 

21

 

9.2

 

Tips

 

and

 

Suggestions

 

22

 

9.3

 

Weld

 

Inspection

 

and

 

Adjustments

 

23

 

10.0

 

Troubleshooting

  

24,

 

25

 

10.1

 

Troubleshooting

 ‐ 

Chart

 

A

 

26

 

10.2

 

Troubleshooting

 ‐ 

Chart

 

B

 

27

 

11.0

 

Parts

 

and

 

Accessories

 

28

 

1.1

 

Product

 

Warranty

 

2

 

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...

Reviews: