Truweld TWE-SC1100 Manuale utente
TRU-WELD EQUIPMENT COMPANY
6400 N. Honeytown Road
Smithville, Ohio 44677
(330) 725-7744 Phone
(330) 669-2473 Fax
TWE@pcorp.com
hp://truweldstudwelding.com
Operations Manual
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 me, weld current, and gas purge
me. The system was designed to be a perfect t 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
2
TRU-WELD EQUIPMENT LIMITED WARRANTY
All goods produced by Truweld Equipment shall be warranted against defects including workmanship and components. No other war-
ranes whether expressed, verbal, or implied will apply. Warranes only apply to the original equipment purchaser.
Warranty claims will be limited to either repair or replacement of the defecve materials by Truweld Equipment. At the opon of Tru-
weld Equipment the locaon of where the warranty evaluaon 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 opon of Truweld Equipment the defect will either be repaired
or replaced. Noce must be provided to Truweld Equipment of a warranty defect within 30 days that the defect or failure is incurred.
Warranes 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 modied
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 connued to be used aer a defect had been found
Equipment which was damaged in any way
Truweld Equipment will never be liable for consequenal 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 SC1650 Power Supply
TWE321 Power Supply SC1900 Power Supply
TWE375 Power Supply SC1950 Power Supply
SC900 Power Supply SC2400 Power Supply
SC1100 Power Supply SC2402 Power Supply
SC1400 Power Supply SC2420 Power Supply
SC1450 Power Supply SC3400 Power Supply
SC1600 Power Supply SC3402 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
Company and Product Informaon
Company Prole
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 naon. Tru-Weld Equipment Company (TWE)
oers a full line of Drawn-Arc and Capacitor Discharge (CD) stud welding equipment, replacement
parts, and accessories.
Our experienced Management and Sta is commied to provide the utmost in quality and service in
every step of our producon, while remaining compeve in the marketplace. It is our goal to meet
our customer's needs more eecvely than our competors through a process of connuous quality
improvement. Our long-standing relaonship with our customers' and suppliers' is our key to conn-
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 Informaon
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 me, weld current, and gas purge me.
The system was designed to be a perfect t for shop use, welding up through 5/8” studs. This is all
contained in a compact, portable package.
Features:
Smooth arc curve targeted for small to medium sized diameter studs
Enhanced Duty Cycle producon requirements
Capable of up to 100 feet of 2/0 welding cable accommodates a large variety of work staon
layouts
Stepless me and current control allow for innite sengs for ne-tuning the welding output
Stud Job Counter that can be reset for every job
On-Demand Fan that cycles on and o when needed.
Complete system Includes:
1000 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
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 precauons menoned. If there is a queson, ask your supervisor!
Safety Symbols
Every eort has been made to protect trained operators from injury or unnecessary risk. Certain
symbols are used throughout this manual to call aenon to safety-related informaon and in-
strucon. The safety symbols in this manual have these meanings:
This symbol indicates Dangerous Situaons. When this symbol is used in this manual,
death or serious bodily harm is possible or probable if the corresponding preventave
measures are not taken. Operators must take cauon in the method and manner of
handling or using the machine when this symbol is displayed.
Safety Precauons
Do not install, operate, or repair the SC1100 welding equipment without reading this manual and
all safety precauons stated within!
This machine was designed and built with operator safety in mind, but safety begins with you! Eve-
ry eort has been made to protect the trained operator from injury. Please become familiar with
the informaon 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 operang stud weld-
ing equipment.
FUMES and OXYGEN DEPLETION
Only weld in areas or rooms where adequate venlaon of weld gases is possible and where
there is not re, smoke or explosion hazards.
When working in a conned 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 locaons near degreasing, cleaning, or spraying operaons. The heat and rays of
the arcs can react with vapors to form highly toxic and irritang gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel. The coang
must be removed from the area to be welded. Coangs and metals containing above elements
can generate toxic fumes when heated to welding temperature.
Stud Welding Safety Precauons
5
ELECTRIC SHOCK
Electric shock can injure or kill!
Precauonary measures must be taken to provide maximum protecon 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 unaended.
Never work in wet clothing, gloves or footwear.
Insulate yourself from work and ground using dry insulaon. Make certain the insulaon is
large enough to cover your full area of physical contact with work and ground.
Inspect all system components, protecve equipment, cables, connectors and gas lines prior
to operang equipment. Never use cables that are longer than necessary.
When tesng 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 connecon with the metal being weld-
ed. The connecon should be as close as possible to the area being welded.
Turn OFF welding power source before servicing unless the procedure specically 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 ashes are painful.
Use a shield with the proper lter and cover plates to protect your eyes from sparks and the
rays of the arc when welding or while observing open arc welding.
Use protecve clothing specically intended for work with welding equipment. It should be
made of durable ame-resistant material to provide ample protecon from the arc rays.
Protect other nearby workers with suitable, non-ammable screening. Cauon other workers
not to watch the arc nor expose themselves to the arc rays or to hot spaer or metal.
Stud Welding Safety Precauons
6
Stud Welding Safety Precauons
WELDING SPARKS
Heat from ames and arcs can start res. Hot slag or sparks can also cause res and
explosions.
Remove all combusble materials from the work area or cover these materials with a protecve non-ammable tarp.
Combusble materials include wood, fabrics, sawdust, liquid and gas fuels, solvents, paints and coangs, paper, etc.
Hot sparks or hot metal can fall through cracks or crevices in oors or wall openings and cause a hidden smoldering
re. Make certain that such openings are protected from hot sparks and metal.
ELECTRIC and MAGNETIC FIELDS
Electric current owing through any conductor causes localized Electro-Magnec Fields (EMF). Welding and cung
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 eects, 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.
Electromagnec elds can irrevocable erase magnec data carriers (computer memory, credit cards, security ID
cards or data storage diskees).
Electromagnec elds may magneze and damage watches or similar digital devices.
PROTECT YOURSELF and OTHERS!
Some welding, cung, and gouging processes are noisy and require ear protecon. The arc, like the sun,
emits ultraviolet (UV) and other radiaon and may injure skin and eyes. Hot metal can cause burns.
Training in the proper use of welding processes and equipment is essenal to prevent accidents.
Always wear safety glasses with side shields in any work area. In conjuncon with eye protecon, welding hel-
mets or face shields are also required.
Use a face shield ed with the correct lter cover plates to protect your eyes, face, neck, and ears from sparks
and rays of the arc when operang or observing operaons. Warn bystanders not to watch the arc and not to
expose themselves to the rays of the electric arc or hot metal.
Wear ameproof type gloves, heavy long-sleeve shirt, cu less trousers, and a welding helmet or cap for hair pro-
tecon, to protect against arc rays and hot sparks or hot metal. A ameproof apron may also be desirable as pro-
tecon against radiated heat and sparks.
Hot sparks or metal can lodge in rolled up sleeves, trouser cus, or pockets. Sleeves and collars should be kept
buoned, 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 producon requirements.
Powerful output for even the largest diameter welding projects.
Time and current control allow for innite sengs for ne-tuning the welding output.
Safety welding interlock keeps system from double-triggering.
SC1100 Product Specicaons
** Specicaons are subject to change without prior nocaon.
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 230 / 460 VAC 3 Phase 60Hz
Fusing Requirements (Slow acng) 230V / 50 Amps
460V / 25 Amps
8
SC1100 Setup and Installaon
Inial Steps
Only qualied personnel should perform this installaon.
Turn the input power o at the disconnect switch or fuse box before working on the welder.
Do not touch electrically hot parts.
This secon provides detailed instrucons for the proper installaon of the TWE SC1100. It is
recommended that these instrucons be followed carefully to allow for the best possible oper-
ang environment.
Handling and Unpacking the Welder
Immediately upon receipt of the welder, inspect the shipment for any damage and nofy the
carrier of such damage before accepng delivery. Then inspect welder for damage which may
have occurred in transit. Aer 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 airow through the welder. If the
equipment is not being installed immediately, store it in a clean, dry, well-venlated area unl in-
stallaon.
Selecng a Locaon
The locaon of the power source should be carefully selected to ensure sasfactory and dependa-
ble service. Choose a locaon relavely close to a properly fused source of electrical power. Use
care against toppling over if the machine is placed on a lted 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 obstrucon.
Electrical Input Requirement
The welding power source is designed to be operated from three-phase, 60Hertz, AC power sup-
ply. Consult your local electrical ulity if you have any quesons on the electrical system at the
present installaon site. The SC1100 should be operated from a separate, fused or circuit-breaker
protected circuit.
9
SC1100 Setup and Installaon
Preparing the Unit for Primary Power
Only qualied personnel should perform this installaon.
Turn the input power o at the disconnect switch or fuse box before working on the welder.
Do not touch electrically hot parts.
Remove the top cover of the SC1100. All of the connecons 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 ghten screws that hold the power leads in place.
Aach the ground wire (Green) to the ground lug of as shown in above.
Once the Primary Power Cable is connected, ghten Power Cable Clamp on the back of the weld-
er, holding the power cable rmly in place.
10
SC1100 Setup and Installaon
Power / Ground Connecons
Electrical Input Requirement
The SC1100 is equipped with an Input Voltage Jumper Block so you can operate the unit from
dierent 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
operaon.
Ground Cable Connecon
The SC1100 is equipped with one ground cable connecon located on the front of the welder
Secure the ground cable to welder and connect the ground clamp to the work surface the.
Indice
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