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

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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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.

5
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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!
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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:

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

Donotinstall,operate,orrepairtheSC2402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

6
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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

7

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.

8

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.
EquippedwithaStudJobCounterthatcanberesetforeveryjoborproject.
On‐DemandFanthatcyclesonandoffwhenneeded.
WeldRange1/4”to1‐1/4”Consistentweldingregardlessofstuddiameter.
DutyCycle1/4”thru5/8”
3/4”
7/8”
1”
Unlimited
18to24perminute
12to14perminute
6to8perminute
DimensionsHeight
Width
Length
Weight

28”(736.6mm)
29”(711.2mm)
36”(914.4mm)
760Lbs.(345kg)
InputVoltages 380/400VAC3Phase50Hz
FusingRequirements(Slowacting)380/100Amps
400/100Amps
SC2402ProductSpecifications
**Specificationsaresubjecttochangewithoutpriornotification.

9

SC2402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SC2402.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,50Hertz,ACpowersup‐
ply.Consultyourlocalelectricalutilityifyouhaveanyquestionsontheelectricalsystematthe
presentinstallationsite.TheSC2402shouldbeoperatedfromaseparate,fusedorcircuit‐breaker
protectedcircuit.

10

SC2402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SC2402.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sidebracketofwelderasshowninFigure1.
♦ OncethePrimaryPowerCableisconnected,tightenPowerCableClamponthebackofthe
welder,holdingthe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.









PowerConnectionsGroundConnection
Figure1
Holddownscrews
Figure2

11

SC2402SetupandInstallation
GroundCableConnections
♦ TheSC2402isequippedwithtwogroundcableconnectionslocatedinthefrontofthewelder
(liftaccesspanel).
♦ TightengroundcabletowelderandsecureotherendtoworksurfaceusingtheHeavy‐DutyC‐
Clamp(seeFigure2).




GroundCableLug(towelder)
GroundCableC‐Clamp(toworksurface)
Figure2‐GroundCable
AccessPanelGroundconnections
Figure1‐FrontofSC2402

12

SC2402SetupandInstallation
WeldCableConnections
♦ TheSC2402isequippedwithtwoweldcableconnectionslocatedinthefrontofthewelder
(liftaccesspanel).
♦ OneendofthecableassemblyconnectsdirectlytotheSC2402andtheotherendconnectsto
thecablingfromtheweldgun.ThewelderendwillhaveacablelugontheHeavyDuty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.





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SC2402,theweldcableendsthatconnectstotheHeavy‐Duty
TWE17000StudGunwillbeafemaleControlCablePlugandafemaleHeavy‐DutyHigh
Temperaturecamlockconnector.
Figure1‐FrontofSC2402
AccessPanelWeldCableConnectionControlCableConnection

13

StudGunSetup
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.

14

StudGunSetup
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.
♦ Toincrease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.
RearCoilYoke
SetScrew
LiftAdjustingScrew
GunBody

15

StudGunSetup
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WeldGunTWE18500Medium‐DutyWeldGun

16

StudGunSetup
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

17

SC2402Operations‐Settings
SC2402PowerSwitch/PowerOn
ThepowerswitchfortheSC2402islocatedontherightfrontof
thewelder’scontrolpanel.Offpositionisverticalwiththe“O”
showing.Onpositionishorizontalwiththe“I”displayed.
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.

SC2402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.
DiagnosticLights

18

SC2402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.







♦ 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10th’sand100th’sofaunit(secondsoramps),dependingonwhetheryouaresetting
TimeorCurrent.
♦ ThereisaChart(seebelow)ofapproximatesettingsforfull‐basediameterstudslocatedto
theleftoftheControls.
TimeButton
AdjustmentDial
CurrentButton
Fine/CoarseSwitch
DigitalDisplays
DIAINCHTIMESECAMPSDCDIADECDIAMM
1/40.200500.2506.35
5/16
3/8
0.300
0.350
550
600
.312
.375
7.93
9.52
7/16
1/2
0.420
0.500
700
900
.437
.500
11.11
12.70
5/8
3/4
0.670
0.830
1200
1600
.625
.750
15.87
19.04
7/8
1
1‐1/4
1.000
1.200
1.800
1800
2100
2400
.875
1.000
1.250
22.22
25.40
31.70
3/4
7/8
.800‐1.4
1.0‐1.6
16‐1900
18‐2200
.750
.875
19.04
22.22
APPROXIMATESETTINGSFORTHRU‐DECKWELDING

19

SC2402Operations‐Settings
WeldCounterandWeldCounterReset
TheSC2402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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.

JobCounterwilldisplayhere
Pressdownandhold

20

SC2402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‐
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”