Truweld TWE-SC900 User manual

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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

2

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TRU‐WELDEQUIPMENTLIMITEDWARRANTY

AllgoodsproducedbyTruweld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Truweld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TruweldEquipmentwillbeatthecustomer’sexpense.AttheoptionofTruweldEquipmentthedefectwilleitherberepaired

orreplaced.NoticemustbeprovidedtoTruweld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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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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

 TWE250PowerSupply SC1900PowerSupply

 TWE321PowerSupply SC1950PowerSupply

 TWE375PowerSupply SC2400PowerSupply

 SC900PowerSupply SC2402PowerSupply

 SC1400PowerSupply SC2420PowerSupply

 SC1450PowerSupply SC3400PowerSupply

 SC1600PowerSupply SC3402PowerSupply

 SC1650PowerSupply

 One(1)yearwarrantyperiodfromdateofpurchase

TWESPCPowerSupplies

  TWP‐2PowerSupply

 NinetyDay(90)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

3

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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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SC900isafullyintegratedstudweldingsystemforferrule‐shieldedandgas‐shieldeddrawnarc

studwelding.TheSC900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through1/2”studs.Thisisallcon‐

tainedinacompact,portable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2/0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.

CompletesystemIncludes:

800AmpPowerSupplyController,TWE19000LightDutystudgun,25feetof#1AWGcombocable,

and15feetof#1AWGgroundcablewithclamp.

4

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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Symbols

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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:



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SC900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.



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personnelnearby.

♦ Weldingfumesandgasescandisplaceairandlowertheoxygenlevelcausinginjuryordeath.Be

surethebreathingairissafe.

♦ 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

5



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.

♦ 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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.

♦ 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

6



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materials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).

♦ Electromagneticfieldsmaymagnetizeanddamagewatchesorsimilardigitaldevices.



PROTECTYOURSELFandOTHERS!



Somewelding,cutting,andgougingprocessesarenoisyandrequireearprotection.Thearc,likethesun,

emitsultraviolet(UV)andotherradiationandmayinjureskinandeyes.Hotmetalcancauseburns.

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.

♦ 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.

7



Features

SmoothArcCurveallowsforawiderangeofwelding.

EnhancedDutyCycleforproductionrequirements.

Powerfuloutputforeventhelargestdiameterweldingprojects.

Timeandcurrentcontrolallowforinfinitesettingsforfine‐tuningtheweldingoutput.

Safety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ofstuddiameter.

DutyCycle14gathru1/4”

3/8”

1/2”

Unlimited

5‐6perminute

2‐3perminute

DimensionsHeight

Width

Length

Weight



12.6”(320mm)

11”(280mm)

22.4”(570mm)

106Lbs.(48kg)

InputVoltages230/460VAC3Phase60Hz

FusingRequirements(Slowacting)230/70Amps

460/35Amps



8



SC900SetupandInstallation

InitialSteps

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SC900.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shipping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SC900shouldbeoperatedfromaseparate,fusedorcircuit‐breaker

protectedcircuit.

9



SC900SetupandInstallation

PreparingtheUnitforPrimaryPower

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SC900.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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.



OncethePrimaryPowerCableisconnected,tightenPowerCableClamponthebackofthe

welder,holdingthepowercablefirmlyinplace.

10



SC900SetupandInstallation

Power/GroundConnections

ElectricalInputRequirement

TheSC900isequippedwithanInputVoltageJumperBlocksoyoucanoperatetheunitfromdif‐

ferent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Connection

TheSC900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.





Table of contents

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