Tru-Weld TWE-SC900 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 SC900 is a fully integrated stud welding system for ferrule‐
shielded and gas‐shielded drawn arc stud welding. The SC900 con‐
tains digital controls for weld time, weld current, and gas purge time.
The system was designed to be a perfect fit for shop use, welding up
through 1/2” studs. This is all contained in a compact, portable pack‐
age.

TWE - SC900

Drawn Arc Gas Short Cycle

Stud Welding System

Version 2.1 03/24/2014

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Summary of Contents for TWE-SC900

Page 1: ...ntegrated stud welding system for ferrule shielded and gas shielded drawn arc stud welding The SC900 con tains digital controls for weld time weld current and gas purge time The system was designed to...

Page 2: ...h 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 Eq...

Page 3: ...cess 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 SC900 is a fully integrated stud welding system for ferrule...

Page 4: ...esigned 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 man...

Page 5: ...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 6: ...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 7: ...welding interlock keeps system from double triggering SC900 Product Specifications Specifications are subject to change without prior notification Weld Range 14ga to 1 2 Consistent welding regardless...

Page 8: ...ng 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 9: ...made are accessi ble with the top cover removed Primary Power Cable Route the Primary Power Cable through the Power Inlet Hole in the center connector on the back side of the welder Connect the power...

Page 10: ...line voltages depending on your requirements Simply plug in the appropriate voltage con nector for either 230VAC red wired connector or 460VAC black wired connector 3 Phase opera tion Ground Cable Co...

Page 11: ...front of the welder Connect stud gun cable assembly directly to the SC900 Plug stud gun control cable plug into the connector on the front of welder Gas line connection When gas shield welding connect...

Page 12: ...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 amount of...

Page 13: ...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 14: ...an 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 damp ener Rotating the dampener co...

Page 15: ...complete the circuit and actuate 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 s...

Page 16: ...e 3 times indicating that there is a good connection SC900 Diagnostic Lights On the Control Panel located below the digital display is a row of diagnostic lights for the welder OUTPUT When the stud gu...

Page 17: ...chosen during setup When setting time or current depress and hold down appropriate button and turn Adjustment Dial clockwise or counter clockwise to the correct setting on the digital display Use the...

Page 18: ...was drawn or not Job Counter Resettable This is a running 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 wel...

Page 19: ...gs from being adjusted The purpose is to allow a meas ure of process control All settings and the counter may be viewed when the lock is activated To activate the lock turn clockwise toward the 3 o cl...

Page 20: ...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 o...

Page 21: ...ud pro trudes beyond the ferrule Make sure work surface is relatively clean so impurities do not affect weld Test the welds at the beginning of each shift or change in stud Check burn off 1 8 color si...

Page 22: ...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 23: ...lift from gun coil trigger is good Bad connection or faulty equipment 1 Test control cable by plugging weld tool directly into unit 4 conductor straight through wiring 2 Check 1 5 amp fuse next to br...

Page 24: ...and 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...

Page 25: ...25 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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