Truweld TWE - SC3402 Operation Manual Download Page 1

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TRU

‐

WELD

EQUIPMENT

COMPANY

6400

Honeytown

Road

Smithville,

Ohio

44677

(330)

725

‐

7744

Phone

(330)

669

‐

2473

Fax

[email protected]

http://truweldstudwelding.com

Operations Manual

The

SC3402

fully

integrated,

dual

‐

gun,

stud

welding

system

with

two

digital

controls

for

time

and

current.

The

system

was

designed

meet

the

most

challenging

stud

welding

jobs

include

weld

thru

‐

deck

applications

(this

also

includes

G90

decking).

TWE - SC3402

Heavy-Duty Dual-Gun Stud Welding System

Version

1.6

10/03/2012

Summary of Contents for TWE - SC3402

Page 1: ...com Operations Manual The SC3402 is a fully integrated dual gun stud welding system with two digital controls for time and current The system was designed to meet the most challenging stud welding jo...

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: ...on Ground Cable Connections 12 6 6 SC3402 Setup and Installation Control Cable Connections 13 7 0 SC3402 Operations Stud Gun Setup 7 1 Stud Gun Setup Initial Steps 14 7 2 Stud Gun Setup Lift Adjustmen...

Page 4: ...nship 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 hesitate to contact us Product Informati...

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: ...or project On Demand Fan that cycles on and off when needed Weld Range 1 4 to 1 1 4 Consistent welding regardless of stud diameter Duty Cycle 1 4 thru 5 8 3 4 7 8 1 1 1 4 Unlimited 22 to 24 per minut...

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: ...uld 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 the hold down nuts Use the schematic...

Page 11: ...ith the top cover removed Primary Power Cable and Ground Connection Route the Primary Power Cable through the Power Inlet Hole see Figure 2 in the top left cor ner on the backside of the welder giving...

Page 12: ...ions located in the front of the welder lift access panel Tighten ground cable to welder and secure other end to work surface using the Heavy Duty C Clamp see Figure 2 Access Panel Ground connections...

Page 13: ...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 SC3402 Access Panel Weld Ca...

Page 14: ...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 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: ...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 increases the a...

Page 17: ...t 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 stud onto surface to...

Page 18: ...at there is a good connection SC3402 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 triggered this li...

Page 19: ...e time or current this will toggle be tween 10th s and 100th s of a unit seconds or amps depending on whether you are setting Time or Current There is a Chart see below of approximate settings for ful...

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: ...t the welds at the beginning of each shift or change in stud Bend two studs 30 degrees af ter cooling AWS Bend Test Check burn off 1 8 3 16 color silver blue and shiny and weld fillet 360 degree Visua...

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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