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Stud 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 for the stud to be welded and attach it to the stud
gun.



Select the proper length leg assemblies for the length of the stud.



Select the proper foot piece best suited for your application.



Select the grip to fit the ferrule which is provided with 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 amount of the stud is inserted in the chuck so that the stud is
held firmly.



Attach the ferrule to the ferrule grip.



Plunge setting; move the leg, foot and ferrule assembly so that the stud protrudes beyond the
ferrule (1/8” for studs 1/2" and under in diameter 3/16” for studs up through 7/8” and 1/4”
for 1” and 1

1/4” diameter studs).



Position this assembly so that the stud moves freely through the ferrule when you slide the
shaft of the stud gun back and forth.

Содержание TWE-SC1100

Страница 1: ...ntegrated stud welding system for ferrule shielded and gas shielded drawn arc stud welding The SC1100 contains digital controls for weld time weld current and gas purge time The system was designed to be a perfect fit for shop use weld ing up through 5 8 studs This is all contained in a compact porta ble package TWE SC1100 Drawn Arc Gas Short Cycle Stud Welding System Version 2 1 03 24 2014 ...

Страница 2: ...n 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 o...

Страница 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 SC1100 is a fully integrated stud welding system for ferrule shielded and gas shielded drawn arc stud welding The SC1100 contains 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...

Страница 4: ...designed and built with operator safety in mind but safety begins with you Eve ry effort has been made to protect the trained operator from injury Please become familiar with the information in this manual 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 co...

Страница 5: ...ine before moving a welding power source Always be sure the work cable makes a good electrical connection with the metal being weld ed 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 ...

Страница 6: ...o 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 or data storage diskettes Electromagnetic fields may magnetize and damage watches or similar digital devices PROTECT YOURSELF and OTHERS Some welding cutting and gouging processes are n...

Страница 7: ...nterlock keeps system from double triggering SC1100 Product Specifications Specifications are subject to change without prior notification Weld Range 14ga to 5 8 Consistent welding regardless of stud diameter Duty Cycle 14ga thru 1 4 3 8 1 2 5 8 Unlimited 7 8 per minute 4 5 per minute 2 3 per minute Dimensions Height Width Length Weight 12 6 320mm 11 280mm 22 4 570mm 125 Lbs 48kg Input Voltages 23...

Страница 8: ...king 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 location of the power source should be carefully selected to ensure satisfactory and dependa ble service Choose a location relatively close to a properly fused source of electrical power Use care ag...

Страница 9: ...e 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 leads Black White Red to the L1 L2 and L3 connectors as shown in photo Firmly tighten screws that hold the power leads in place Attach the ground wire Green to the ground lug of as shown in above On...

Страница 10: ...nt line voltages depending on your requirements Simply plug in the appropriate voltage connector for either 230VAC red wired connector or 460VAC black wired connector 3 Phase operation Ground Cable Connection The SC1100 is equipped with one ground cable connection located on the front of the welder Secure the ground cable to welder and connect the ground clamp to the work surface the ...

Страница 11: ... front of the welder Connect stud gun cable assembly directly to the SC1100 Plug stud gun control cable plug into the connector on the front of welder Gas line connection When gas shield welding connect the gas line from the foot piece of the stud gun into the gas fitting on the front of the SC1100 by easy quick connect fitting ...

Страница 12: ...e 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 the stud is inserted in the chuck so that the stud is held firmly Attach the ferrule to the ferrule grip Plunge setting move the leg foot and ferrule assembly so that the stud protrudes beyond the f...

Страница 13: ...anging 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 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 c...

Страница 14: ...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 damp ener Rotating the dampener cover counter clockwise increases the amount of free travel ...

Страница 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 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 t...

Страница 16: ...ating that there is a good connection SC1100 Diagnostic Lights On the Control Panel located below the digital display is a row of diagnostic lights for the welder WELD When the stud gun is triggered this light comes on to indicate that the OCV is present at the output terminals CONT This light indicates that contact is being made between the work and the stud TRIG When the stud gun is triggered th...

Страница 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 Fine Coarse Switch for setting the appropriate time or current this will toggle between 10 s or 100 s of amps and 10th s and 100th s of a second To adjust gas purge time hold both the TIME and AMPS b...

Страница 18: ...c 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 weld will be recorded on the Current digital display If the switch is in the Coarse position the weld will still be counted but will not be displayed You can also view the Job Counter total by depressi...

Страница 19: ...ings 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 clock position To deactivate the lock turn counter clockwise toward the 12 o clock position ...

Страница 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 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...

Страница 21: ...stud 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 silver blue and shiny and weld fillet 360 degree Visually inspect all welds Thru Deck Stud Welding Helpful Hints and Suggestions Keep weld studs and ferrules clean and dry Never attempt thru deck weld...

Страница 22: ...ms 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 from the weld time being set too long and or the current being too low Reduce the current and or reduce the weld time to correct Weld Collar Off Center This is when the collar is heavy or thick on o...

Страница 23: ...no 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 5 amp fuse next to breakers 3 Check hand tool coil resistance 12 40 ohms 4 Remove side panel without louvers to examine lights on the left circuit board Report your findings to a TWE Rep for troubleshooting assistance Gun...

Страница 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 transformer Weld gun lifts but does not plunge Gun maintenance If this happens it is most likely binding inside of the gun Per form routine gun maintenance or replace gun if needed All tests should b...

Страница 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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