SC1900 User`s Manual
Contents
1. SC1900 Power Switch Power On The power switch for the C1900 is located on the right front of the welder s control panel The rotary switch is off in the vertical position 0 The switch turned to the horizontal position I turns the unit on When the welder is turned on the digital display will go through a self diagnostic check This takes approximately 3 to 5 seconds and then the digital display will show the last time and current setting This denotes that the unit is ready to go When connected to the welder the stud gun will actuate 3 times 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 triggered this light comes on to indicate that the OCV is present at the output terminals TRIGGER When the stud gun is triggered this light comes on to indicate that the trigger circuit is functioning properly and that the welding unit is receiving feedback from the stud gun POWER When this light is lit it indicates that there is an error TEMP When this light is lit it indicates that either the main transformer or weld bridge has reached maximum temperature and that the unit will not function until it is cooled REMOTE This function is not currently in use TRU WELD EQUIPMENT Diagnostic Lights g O00 TIME lt Fine Coarse2. Lift Adjusting Screw _ _ Gun Body 15 Free Travel Adjustment This adjustment 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 Dampener Cover TWE17000 Heavy Duty Stud Gun 16 Attaching the stud gun to start welding Select the gun control cable and weld cable that is recommended for the specific type of welder and the job Attach stud gun to weld and control cable extension Actuate the stud gun without placing it on the surface to be welded to assure that the con nection through the control cable is correct to 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 the welded stud Do not depress trigger when removing gun from stud Remove the ferrule by breaking it off and inspect the weld Make proper adjustments as needed Figure 1 TWE17000 Heavy Duty Stud Gun Weld Cable Control Cable 17 C1900 Operations Settings
3. TWE C1900 Stud Welding System 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 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 Version1 5 10 03 2012 TRU WELD EQUIPMENT LIMITED WARRANTY All goods produced by Tru Weld Equipment shall be warranted against defects including workmanship and components No other war ranties whether expressed verbal or implied will apply Warranties only apply to the original equipment purchaser Warranty claims will be limited to either repair or replacement of the defective materials by Tru Weld Equipment At the option of Tru Weld Equipment the location of where the warranty evaluation and repairs are made will be determined All warranty claim items re turned to Tru Weld Equipment will be at the customer s expense At the option of Tru Weld Equipment the defect will either be re paired or replaced Notice must be provided to Tru Weld Equipment of a warranty defect within 30 days that the defect or failure is incurred Warranties are not transferable This warranty does not apply for equipment which is used improperly in any fashion including but not ex
4. EEA AMES q nC OC D C1900 Operations Settings Setting Welding Controls Time and Current The time and current controls are located on the front of the welder The controls consist of a Time Button Current Button Adjustment Dial and a Fine Coarse Switch The digital display will indicate the settings chosen during setup Time Button Fine Coarse Switch Current Button Digital Displays Adjustment Dial When setting time or current depress and hold down appropriate button and turn Adjust ment 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 be tween 10 s or 100 s of amps and 10th s and 100th s of a second There is a Chart see below of approximate settings for full base diameter studs located to the left of the Controls TIME SEC AMPS DC DIA DEC Ze e 0 300 550 0 350 600 7 16 0 420 0 500 0 670 830 19 C1900 Operations Settings Weld Counter and Weld Counter Reset The SC1900 is equipped with different counters to display the number of times the unit has drawn an arc or the stud gun has been actuated Perpetual Weld Counter Non resettable This is a running total of every time an arc is drawn on the machine This is programmed from the factory and can not be reset Perpetual Gun Counter Non resettable This is a running total of
5. Test the power loop by making welds on a test piece us ing only the starter cable set Test 3 phase power to control contactor Check taps if applicable on main transformer Weld gun lifts but does not Gun maintenance If this happens it is most likely binding inside of the gun Per plunge form routine gun maintenance or replace gun if needed All tests should be performed by a qualified person Always turn off power to the welder before working on or testing components within the welder Contact your TRU WELD Equipment Representative for replacement parts and for servicing your welding equipment 25 C1900 Troubleshooting Chart A Acceptable R amp S Control Wire Schematics For Weld Tools The Tru Weld Equipment Digital Series Welders will accept any one of these configurations without changing any wiring in the machine SOCKET VIEW PLUG VIEW FROM UNIT FROM GUN h a TRU WELD 4 WIRE PREFERRED TRIGGER x TRIGGER y COIL z COIL PROWELD KSM 4 WIRE TRIGGER x COIL y COIL z TRIGGER TRW NELSON 3 WIRE TRIGGER x NOT USED y COIL z COIL AND TRIGGER When making your own tool extensions 16 4 cable is recommended NOTE Make sure the ground pin is isolated from the case Contact Tru Weld Equipment with any questions on connections 26 C1900 Troubleshooting Chart B Circuit board control box fuse breaker and L E D layout Tru Held Equipment
6. Test control cable by plugging weld tool directly into unit lift from gun coil trigger is faulty equipment 4 conductor straight through wiring good Check 10 amp fuse on control board box next to break ers Check hand tool coil resistance 12 40 ohms Locate Touch Trigger Control Board 16001 Chart B Check and note the operation of the driver LED s and report the status Gun lifts no weld arc drawn Bad connection or 1 Check connections for ground and weld tool leads faulty equipment 2 Check if contact LED on control panel lights when stud is touched to work surface closing circuit Check the two circuit breakers on the control board box Check to see if you have the sustaining arc a small blue arc for the duration of the weld time Check to see if the stud sparks at the end of the weld cycle hot plunge Locate Touch Trigger Control Board 16001 Chart B Check and note the operation of the driver LED s and report the status 24 C1900 Troubleshooting Problem Possible Cause Unit stops welding Over heating 1 Ifthe fan is running allow unit to cool OverTemp LED is on 2 Slow down welding rate fewer studs per minute Any fault in the OverTemp Thermostat Circuit will shut the system down Weld output erratic or weak Adjustments or set Check welding hand tool set up lift plunge and acces tings sory adjustments Check ALL weld current carry leads and connections in cluding grounds
7. competitors through a process of continuous quality improvement 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 hesitate to contact us Product Information The SC1900 is a fully integrated stud welding system with two digital controls for time and current The system was designed to be a perfect fit for shop use excelling at small to medium sized diame ter studs all in a compact affordable package Features Smooth arc curve targeted for small to medium sized diameter studs Enhanced Duty Cycle production requirements Capable of up to 100 feet of 4 0 welding cable accommodates a large variety of work station lay outs Stepless time and current control allow for infinite settings for fine tuning the welding output Stud Job Counter that can be reset for every job Complete system Includes 1800 Amp power supply TWE17000 Heavy Duty stud gun 35 feet of 4 0 combo cable and 25 feet of 4 0 ground cable Stud Welding Safety Precautions Safety is everyone s responsibility TRU WELD designs every machine with safety in mind and a safe work environment depends largely on you Do not install operate or repair this equipment without carefully reading this manual and observ ing all of the safety precautions mentioned If there is a question ask your supervisor Safety
8. gun not being flush or perpendicular to the base material during welding 23 C1900 Troubleshooting Problem Possible Cause No power Test 3 phase power to control contactor Check taps if applicable on main transformer Check voltage selection plug near control transformer Check fuse located on control transformer Look for power available LED on control transformer eS SS a Make these checks before contacting a TWE Rep Fan does not run when unit is This is normal The fan will cycle on when the main bridge has reached turned on nominal operating temperature Ambient temperature of the weld site should also be taken in consideration Fan runs continuously does Thermostat circuit A fault in the thermostatic circuit will cause the fan to run not cycle on off continuously Call your TWE Rep for repairs Unit turns on coil boot test is Bad connection or Test control cable by plugging weld tool directly into unit good no trigger from weld faulty equipment 4 conductor straight through wiring gun 2 Check gun trigger resistance lt 100 ohms when closed Check to see if trigger LED on control panel responds Check to see if weld tool is wired according to one of the three diagrams in Chart A see page 25 Locate Touch Trigger Control Board 16002 Chart B Check and note the operation of the driver LED s and report the status Unit turns on no coil test no Bad connection or
9. RS emits ultraviolet UV and other radiation and may injure skin and eyes Hot metal can cause burns f Some welding cutting and gouging processes are noisy and require ear protection The arc like the sun Training in the proper use of welding processes and equipment is essential to prevent accidents Always wear safety glasses with side shields in any work area In conjunction with eye protection welding hel mets or face shields are also required Use a face shield fitted with the correct filter cover plates to protect your eyes face neck and ears from sparks and rays of the arc when operating or observing operations Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric arc or hot metal Wear flameproof type gloves heavy long sleeve shirt cuff less trousers and a welding helmet or cap for hair pro tection to protect against arc rays and hot sparks or hot metal A flameproof apron may also be desirable as pro tection against radiated heat and sparks e Hot sparks or metal can lodge in rolled up sleeves trouser cuffs or pockets Sleeves and collars should be kept buttoned and open pockets eliminated from the front of clothing SC1900 Product Specifications Weld Range 1 4 to 7 8 Consistent welding regardless of stud diameter Duty Cycle 1 4 thru 3 8 Unlimited 1 2 22 to 24 per minute 5 8 9 to 10 per minute 3 4 4 to 5 per minute 7 8 3 to 4 per minut
10. Symbols Every effort has been made to protect trained operators from injury or unnecessary risk Certain symbols are used throughout this manual to call attention to safety related information and in struction The safety symbols in this manual have these meanings A This symbol indicates Dangerous Situations When this symbol is used in this manual death or serious bodily harm is possible or probable if the corresponding preventative measures are not taken Operators must take caution in the method and manner of handling or using the machine when this symbol is displayed Safety Precautions Do not install operate or repair the SC1900 welding equipment without reading this manual and all safety precautions stated within This machine was 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 manual to minimize the risk of shock or injury A STUD WELDING CAN BE HAZARDOUS ALWAYS PROTECT YOURSELF AND OTHERS FROM POSSIBLE INJURY OR DEATH KEEP CHILDREN AWAY Operators who have a pacemaker should consult with their physician before operating stud weld ing equipment FUMES and OXYGEN DEPLETION Only weld in areas or rooms where adequate ventilation of weld gases is possible and where there is not fire smoke or explosion hazards When working in a confined space always have trained support pe
11. Ta Lie _ t6ce2ra303 T pa g7 ll fan i From front of unit Breaker Fuse L E D Board 16000 16001 16002 B16001 16060 Name Digital Control Pilot Arc Touch Trigger Gun Control Dual Gate Drive Gun Control Accessory L1 Gate Power GPri SSR1 L1 PWRA F1 3 LG4 COIL 36 Volt Supply Gun Primary Touch Supply YZ Output 15 Vdc Supply LED 2 L2 5Vdc GSec SSR2 L6 5VDC LG3 GUN C RED Q1 Pos 5V Supply Gun Secondary Digital Supply GLV Signal TR1 Active L3 15Vdc LR6 PA L2 WORK LR3 GUN C A GREEN Pos 15V Supply D1 Pilot Arc Output Stud On Work GC FUSE Indicator Channel A Selected Indicator L4 15Vdc LR4 COIL L3 TRIG LG2 GUN P B GREEN Neg 15V Supply BR1 2 Output Trigger Indicator GHV Signal Channel B Selected LG1 PAph2 L5 2WIRE LR2 GUN P RED Q2 Drive Signal Input 2 Supply GP FUSE TR2 Active Indicator LED 5 LED 6 LR5 PAph1 L4 AWIRE LG1 ACCESS Drive Signal Input 1 Supply ACC Signal ooo Drive Signal ACC FUSE Indicator AGC 10A 250V 1A 125V FST 10A 250V FST X1 5X20 mm 5X20 mm Hand Tool 1 Coil LED 1 PWRA Hand Tool 2 Coil 27 SC1900 Parts and Accessories TRU WELD Equipment manufactures and stock a full line of stud welding parts and accessories for all of your stud welding needs most accessories listed below are for 3 4 and larger studs Closed Ferrule Grips 1 Long Brass Split Ferrule Grip 1 Long Brass Adjustable Chucks Headed Chuck
12. and Installation SC1900 Setup and Installation Initial Steps 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 SC1900 Setup and Installation Control Cable Connections Stud Gun Setup Initial Steps 7 2 Stud Gun Setup Lift Adjustment 15 7 3 Stud Gun Setup Plunge Adjustment 16 Stud Gun Setup Cable Connections SC1900 Operations Unit Power Diagnostic Lights 8 2 SC1900 Operations Setting Time and Current 19 8 SC1900 Operations Setting Job Counter Step by Step 9 2 Tips and Suggestions 22 Weld Inspection and Adjustments 10 1 Troubleshooting Chart A 10 2 Troubleshooting Chart B 27 11 0 Parts and Accessories 28 Company and Product Information Company Profile Tru Weld Stud Welding has been making weld studs since 1959 and since 1970 we have been pro ducing our own line of high quality stud welding equipment Tru Weld is located in Medina Ohio and has product and equipment distributors across the nation Tru Weld Equipment Company TWE of fers a full line of Drawn Arc and Capacitor Discharge CD stud welding equipment replacement parts and accessories Our experienced Management and Staff is committed to provide the utmost in quality and service in every step of our production while remaining competitive in the marketplace It is our goal to meet our customer s needs more effectively than our
13. clusive 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 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 Tru Weld Equipment will never be liable for consequential damages loss or expense occurring directly or indirectly from the use of the equipment covered in this warranty All cables cable sets and connectors are not warranted Two 2 year warranty period from date of purchase SC3402 Power Supply SC3400 Power Supply SC2402 Power Supply SC2400 Power Supply SC1600 Power Supply SC1400 Power Supply SC1900 Power Supply TWE250 Power Supply TWE321 Power Supply TWE375 Power Supply One 1 year warranty period from date of purchase TWESPC Power Supplies TWP 2 Power Supply Ninety Day warranty period from date of purchase Excluding cables and connectors TWE70000 HD Arc stud gun TWE18500 MD Arc stud gun TWE19000 LD Arc stud gun TWEG CD stud gun TWEHDG Heavy Duty CD stud gun Table of Contents Section Description Page 1 0 Cover 1 1 1 Product Warranty 2 2 0 Table of Contents 3 Company Profile and Product Information Safety Precautions Symbols and Description 4 2 Safety Precautions Electric Shock 6 4 3 Safety Precautions Welding Sparks 7 Product Specifications 6 0 SC1900 Setup
14. e 22 559mm 25 635mm 30 762mm 390 Lbs 177kg Input Voltages 230 460 575 VAC 3 Phase 60Hz Fusing Requirements Slow acting 230 120Amps 460 60 Amps 575 50 Amps Features Smooth arc curve targeted for small to medium sized diameter studs Enhanced Duty Cycle production requirements Capable of up to 100 feet of 4 0 welding cable accommodates a large variety of work station layouts Stepless time and current control allow for infinite settings for fine tuning the welding output Stud Job Counter that can be reset for every job On Demand Fan that cycles on and off when needed Specifications are subject to change without prior notification SC1900 Setup and Installation Initial Steps 1 Only qualified personnel should perform this installation Turn the input power off at the disconnect switch or fuse box before working on the welder Do not touch electrically hot parts This section provides detailed instructions for the proper installation of the TWE SC1900 It is recommended that these instructions be followed carefully to allow for the best possible operat ing environment Handling and Unpacking the Welder Immediately upon receipt of the welder inspect the shipment for any damage and notify the carrier of such damage before accepting delivery Then inspect welder for damage which may have occurred in transit After removing the components from the shipp
15. e power cable firmly in place see Figure 2 Allow enough play in cable so that the cable is free from any obstructions and does not lay across jumper board Figure 1 Figure 2 1PiaGaelpi pPi aGaltirraa Gal 12a Galt 2i aoelt224Ge 0 ae ee 0s ae eee O i EEE A Power Inlet in back of unit Ground Connection Power Connections 11 SC1900 Setup and Installation Ground Cable Connections The SC1900 is equipped with one ground cable connection 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 Figure 1 Front of SC1900 AJ Ground connection Access Panel Figure 2 Ground Cable aA Ground Cable Lug to welder Ground Cable C Clamp to work surface SC1900 Setup and Installation Weld Cable Connections The SC1900 is equipped with two weld cable connections located in the front of the welder lift access panel One end ofthe cable assembly connects directly to the SC1900 and the other end connects to the cabling from the weld gun The welder end will have a cable lug on the 4 0 Weld Cable and a male 4 pole plug on the Control Cable Tighten weld cable 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
16. eld e Test the welds at the beginning of each shift or change in stud Bend two studs 30 degrees af ter cooling AWS Bend Test e Check burn off 1 8 3 16 color silver blue and shiny and weld fillet 360 degree e Visually inspect all welds To ensure satisfactory welds bend test a minimum of one stud out of every one hundred by striking stud with a hammer and bending the stud 15 from its original axis 22 SC1900 Operations Welding Visual Weld Inspection and Adjustments I Good Weld After shooting the stud break away ferrule and visually inspect the weld The collar should be smooth and even around the entire stud Partial Weld This is when the collar does not extend around the entire perimeter of the base of the stud This normally occurs when the weld power is set too low Irregular Weld This is when the collar forms 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 one half of the base of the weld stud The stud may also be tilted This usually results from movement from the gun during the weld process or the
17. equirements 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 the hold down nuts Use the schematic below for the jumper setting to suit your line voltage requirement Figure 1 Jumper Block Jumpers Z 5 f 234 a Y a a SELI a 23406 Sg fo 5 om m9 O s ao m O5 Figure 2 Fuses AN tk gk 234g ee 0000 e000 ooo The welder is supplied with spare fuses lo cated below the jumper block 10 SC1900 Setup and Installation Preparing the Unit for Primary Power 1 Only qualified personnel should perform this installation Turn the input power off at the disconnect switch or fuse box before working on the welder Do not touch electrically hot parts Remove the top cover of the SC1900 All of the connections that will need to be made are accessi ble with the top cover removed Primary Power Cable Route the Primary Power Cable through 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 the power leads in place Attach the ground wire Green to the ground lug of as shown in Figure 1 Once the Primary Power Cable is connected tighten Power Cable Clamp on the back of the welder holding th
18. erials include wood fabrics sawdust liquid and gas fuels solvents paints and coatings paper etc Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire Make certain that such openings are protected from hot sparks and metal ELECTRIC and MAGNETIC FIELDS Electric current flowing through any conductor causes localized Electro Magnetic Fields EMF Welding and cutting current creates EMF around welding cables and welding machines Operators having pacemakers should consult their physician before welding EMF may interfere with some type of pacemakers Exposure to EMF may have other health effects which are unknown Operators should use the following procedures to minimize exposure to EMF Route the work cables together Secure them with electrical tape when possible Never coil the work cable around any part of your body Do not place your body between the work cables Route cables on the same side of your body Connect the work cable to the work piece as close as possible to 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 gt gt gt gt gt gt o Electromagnetic fields may magnetize and damage watches or similar digital devices PROTECT YOURSELF and OTHE
19. every time the stud gun is actuated whether an arc 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 depressing the Adjustment Dial while the switch is in the Coarse position To Reset the Job Counter 1 Turn off unit 2 Depress and hold down Time and Current buttons 3 Turn on machine 4 Keep holding down buttons until OUTPUT light flashes then release the buttons 5 Job Counter will now be set at 0 6 Weld count will now register on Current digital display TRU WELD EQUIPMENT aja TIME SECONDS Press down and hold lt Fine Coarse A AMES Fi D J U S i Job Counter will display here 20 SC1900 Operations Welding Stud Welding Step by Step The weld gun is positioned over the base material and the main gun spring is partially compressed Hold gun perpendicular to work surface and hold ferrule firmly against the surface The trigger is pressed and the stud lifts off the base drawing an arc The arc melts the end of the weld stud and the base material below The arc shield ferrule concentrates the heat below the weld stud and contains the mol
20. his assembly so that the stud moves freely through the ferrule when you slide the shaft of the stud gun back and forth PLUNGE LENGTH FERRULE we a FILE F e E t N TRIGGER CHUCK FOOT LEG LEG LEG ADJUSTMENT SCREW WELD CABLE Lift Set the lift when all of the accessories and stud have been properly set on the stud gun prior to welding Plug the control connector of the stud gun directly into the stud welder do not attach the weld cable Turn on the stud welder and actuate the trigger of the stud gun with the stud and fer rule in place Note the retraction of the shaft of the stud gun This is designated as the Lift The lift setting should be about 3 32 for general welding applications and studs ranging 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 Toincrease lift rotate the lift adjustment screw counter clockwise and to decrease lift rotate clockwise With each turn check the lift by actuating the stud gun until the desired lift is achieved Tighten the socket set screws to hold the lift adjustment screw in place to secure the selected setting Replace the back cap of the stud gun Set Screw Rear Coil Yoke
21. ing container s check the container for any loose parts Remove all packing materials Visually check all air passages of power source for any packing 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 depend able service Choose a location relatively close to a properly fused source of electrical power Use care against toppling over if the machine is placed on a tilted surface or plane It is important that the machine be located in an open area where air can circulate freely through the front and rear openings If space is at a premium leave at least 1 foot 300 mm of clearance between the rear of the power source and wall or other obstruction Electrical Input Requirement The welding power source is designed to be operated from three phase 60Hertz AC power sup ply Consult your local electrical utility if you have any questions on the electrical system at the present installation site The SC1900 should be operated from a separate fused or circuit breaker protected circuit SC1900 Setup and Installation Power Connection Diagrams Electrical Input Requirement The SC1900 is equipped with an Input Voltage Jumper Block so you can operate the unit from dif ferent line voltages depending on your r
22. one hand free Disconnect input power conductors from de energized supply line 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 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 A Never use the power source to provide heat for thawing frozen pipes ARC RAYS and EYE PROTECTION Arc rays can injure eyes and burn skin Arc flashes are painful Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or while observing open arc welding Use protective clothing specifically intended for work with welding equipment It should be made of durable flame resistant material to provide ample protection from the arc rays Protect other nearby workers with suitable non flammable screening Caution other workers not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal Stud Welding Safety Precautions WELDING SPARKS Heat from flames and arcs can start fires Hot slag or sparks can also cause fires and explosions Remove all combustible materials from the work area or cover these materials with a protective non flammable tarp Combustible mat
23. rsonnel nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe e Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arcs can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel The coating must be removed from the area to be welded Coatings and metals containing above elements can generate toxic fumes when heated to welding temperature Stud Welding Safety Precautions ELECTRIC SHOCK Electric shock can injure or kill Precautionary measures must be taken to provide maximum protection against electri cal shock Do not touch live or energized electrical parts or store metallic objects near power Ground the work or metal to be welded to a good electrical earth ground Do not leave an energized machine unattended Never work in wet clothing gloves or footwear A gt a Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground Inspect all system components protective equipment cables connectors and gas lines prior to operating equipment Never use cables that are longer than necessary When testing a live unit use the one hand method Do not put both hands inside of the unit Keep
24. s Stud Diameter Part Number Stud Diameter Part Number 3 4 CN 075 3 4 CH 075 7 8 CN 087 7 8 CH 087 1 CN 100 1 CH 100 Gun Legs Thru Deck Accessories Length amp Diameter 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 B 0021 3 wenom wee ue as SC Ee a C E e 28 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 MADE IN THE USA 29
25. ten metal within the weld zone Do not move weld gun during 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 ferrule is broken away and discarded Visually inspect weld Note when determining finished length required for the particular application keep in mind the reduction in length burn off from stud welding operations TRU WELD stud lengths are al ways given before weld Diameter of Stud Reduction in Length 1 4 thru 1 2 1 8 5 8 thru 7 8 3 16 1 and over 1 4 21 SC1900 Operations Welding Stud Welding Helpful Hints and Suggestions e Keep weld studs and ferrules clean and dry e Set the time for the appropriate weld base diameter see chart on page 19 e Set the amperage for the appropriate weld base diameter see chart on page 19 e Make sure the negative polarity is to the weld stud gun and ensure a good clean ground con nection e Align accessories so they are centered and adjust legs so that 3 16 to 1 4 of the stud pro trudes beyond the ferrule e Make sure work surface is relatively clean so impurities do not affect w
26. y amp GROUND CONTROL CABLE Access Panel Control Cable Connection Weld Cable Connection After the cables are connected to the welder it is time to configure your weld gun for its specific job Once the gun is configured and set up properly the gun cables will connect to the weld cables For the SC1900 the weld cable ends that connects to the Heavy Duty TWE17000 Stud Gun will be a female Control Cable Plug and a female camlock connector 13 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 diameter studs Position t
Download Pdf Manuals
Related Search