Truweld Equipment TWE - SC2402 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SC2402isafullyintegratedstudweldingsystemwithtwodigitalcon‐
trolsfortimeandcurrent.Thesystemwasdesignedtomeetthemost
challengingstudweldingjobstoincludeweldthru‐deckapplications.
TWE - SC2402
Heavy Duty Stud Welding System
Version3.008/14/2013

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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

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TableofContents
SectionDescriptionPage
1.0Cover1
2.0TableofContents3
3.0CompanyProfileandProductInformation4
4.0SafetyPrecautions
4.1SafetyPrecautions‐SymbolsandDescription5
4.2SafetyPrecautions‐ElectricShock6
4.3SafetyPrecautions‐WeldingSparks 7
5.0ProductSpecifications8
6.0SC2402SetupandInstallation
6.1SC2402SetupandInstallation‐InitialSteps9
6.2SC2402SetupandInstallation‐PrimaryPower10
6.3SC2402SetupandInstallation‐GroundCableConnections11
6.4SC2402SetupandInstallation‐ControlCableConnections12
7.0SC2402Operations‐StudGunSetup
7.1StudGunSetup‐InitialSteps13
7.2StudGunSetup‐LiftAdjustment14
7.3StudGunSetup‐PlungeAdjustment15
7.4StudGunSetup‐CableConnections16
8.0SC2402Operations‐Settings
8.1SC2402Operations‐UnitPower/DiagnosticLights17
8.2SC2402Operations‐SettingTimeandCurrent18
8.3SC2402Operations‐SettingJobCounter19
9.0SC2402Operations‐Welding
9.1StepbyStep20
9.2TipsandSuggestions21
9.3WeldInspectionandAdjustments22
10.0Troubleshooting 23,24
10.1Troubleshooting‐ChartA25
10.2Troubleshooting‐ChartB26
11.0PartsandAccessories27
1.1ProductWarranty2

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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SC2402isafullyintegratedstudweldingsystemwithtwodigitalcontrolsfortimeandcurrent.
Thesystemwasdesignedtomeetthemostchallengingstudweldingjobstoincludeweldthru‐deck
applications.
Features:
♦ Enhanceddutycycleforproductionrequirementsandpowerfuloutputforeventhelargestdi‐
ameterjobs.
♦ Digitaltimeandcurrentcontrolallowforinfinitesettingsforfinetuningtheweldingoutput.
♦ Safetyweldinginterlockkeepssystemfromdoubletriggeringandsavesonchuckwear.
♦ StudJobcounterwhichcanberesetperjob.
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CompletesystemIncludes:
Powersupplycontroller,TWE17000heavydutystudgun,50ftof4/0weldandcontrolcableand25ft
of4/0groundcablew/HDclamp.

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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.
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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!
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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:
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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.
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SafetyPrecautions
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Donotinstall,operate,orrepairtheSC2402weldingequipmentwithoutreadingthismanualand
allsafetyprecautionsstatedwithin!
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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.
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STUDWELDINGCANBEHAZARDOUS.ALWAYSPROTECTYOURSELFANDOTHERS
FROMPOSSIBLEINJURYORDEATH.KEEPCHILDRENAWAY.
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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