Truweld TWE-SC1100 User manual

TRU-WELD EQUIPMENT COMPANY
6400 N. Honeytown Road
Smithville, Ohio 44677
[phone] Phone
[phone] Fax
TWE@pcorp.com
hp://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-
ranes whether expressed, verbal, or implied will apply. Warranes only apply to the original equipment purchaser.
Warranty claims will be limited to either repair or replacement of the defecve materials by Truweld Equipment. At the opon of Tru-
weld Equipment the locaon of where the warranty evaluaon 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 opon of Truweld Equipment the defect will either be repaired
or replaced. Noce must be provided to Truweld Equipment of a warranty defect within 30 days that the defect or failure is incurred.
Warranes 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 modied
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 connued to be used aer a defect had been found
Equipment which was damaged in any way
Truweld Equipment will never be liable for consequenal 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 Informaon
Company Prole
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 naon. Tru-Weld Equipment Company (TWE)
oers a full line of Drawn-Arc and Capacitor Discharge (CD) stud welding equipment, replacement
parts, and accessories.
Our experienced Management and Sta is commied to provide the utmost in quality and service in
every step of our producon, while remaining compeve in the marketplace. It is our goal to meet
our customer's needs more eecvely than our competors through a process of connuous quality
improvement. Our long-standing relaonship with our customers' and suppliers' is our key to conn-
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 Informaon
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 producon requirements
 Capable of up to 100 feet of 2/0 welding cable accommodates a large variety of work staon
layouts
 Stepless me and current control allow for innite sengs 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 precauons menoned. If there is a queson, ask your supervisor!
Safety Symbols
Every eort has been made to protect trained operators from injury or unnecessary risk. Certain
symbols are used throughout this manual to call aenon to safety-related informaon and in-
strucon. The safety symbols in this manual have these meanings:
This symbol indicates Dangerous Situaons. When this symbol is used in this manual,
death or serious bodily harm is possible or probable if the corresponding preventave
measures are not taken. Operators must take cauon in the method and manner of
handling or using the machine when this symbol is displayed.
Safety Precauons
Do not install, operate, or repair the SC1100 welding equipment without reading this manual and
all safety precauons stated within!
This machine was designed and built with operator safety in mind, but safety begins with you! Eve-
ry eort has been made to protect the trained operator from injury. Please become familiar with
the informaon 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 operang stud weld-
ing equipment.
FUMES and OXYGEN DEPLETION
 Only weld in areas or rooms where adequate venlaon of weld gases is possible and where
there is not re, smoke or explosion hazards.
 When working in a conned 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 locaons near degreasing, cleaning, or spraying operaons. The heat and rays of
the arcs can react with vapors to form highly toxic and irritang gases.
 Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel. The coang
must be removed from the area to be welded. Coangs and metals containing above elements
can generate toxic fumes when heated to welding temperature.
Stud Welding Safety Precauons

5
ELECTRIC SHOCK
Electric shock can injure or kill!
Precauonary measures must be taken to provide maximum protecon 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 unaended.
 Never work in wet clothing, gloves or footwear.
 Insulate yourself from work and ground using dry insulaon. Make certain the insulaon is
large enough to cover your full area of physical contact with work and ground.
 Inspect all system components, protecve equipment, cables, connectors and gas lines prior
to operang equipment. Never use cables that are longer than necessary.
 When tesng 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 connecon with the metal being weld-
ed. The connecon should be as close as possible to the area being welded.
 Turn OFF welding power source before servicing unless the procedure specically 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 protecve clothing specically intended for work with welding equipment. It should be
made of durable ame-resistant material to provide ample protecon from the arc rays.
 Protect other nearby workers with suitable, non-ammable screening. Cauon other workers
not to watch the arc nor expose themselves to the arc rays or to hot spaer or metal.
Stud Welding Safety Precauons

6
Stud Welding Safety Precauons
WELDING SPARKS
Heat from ames and arcs can start res. Hot slag or sparks can also cause res and
explosions.
Remove all combusble materials from the work area or cover these materials with a protecve non-ammable tarp.
Combusble materials include wood, fabrics, sawdust, liquid and gas fuels, solvents, paints and coangs, 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-Magnec Fields (EMF). Welding and cung
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 eects, 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.
 Electromagnec elds can irrevocable erase magnec data carriers (computer memory, credit cards, security ID
cards or data storage diskees).
 Electromagnec elds may magneze and damage watches or similar digital devices.
PROTECT YOURSELF and OTHERS!
Some welding, cung, and gouging processes are noisy and require ear protecon. The arc, like the sun,
emits ultraviolet (UV) and other radiaon and may injure skin and eyes. Hot metal can cause burns.
Training in the proper use of welding processes and equipment is essenal to prevent accidents.
 Always wear safety glasses with side shields in any work area. In conjuncon with eye protecon, 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 operang or observing operaons. 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-
tecon, to protect against arc rays and hot sparks or hot metal. A ameproof apron may also be desirable as pro-
tecon against radiated heat and sparks.
 Hot sparks or metal can lodge in rolled up sleeves, trouser cus, or pockets. Sleeves and collars should be kept
buoned, 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 producon requirements.
Powerful output for even the largest diameter welding projects.
Time and current control allow for innite sengs for ne-tuning the welding output.
Safety welding interlock keeps system from double-triggering.
SC1100 Product Specicaons
** Specicaons are subject to change without prior nocaon.
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 acng) 230V / 50 Amps
460V / 25 Amps

8
SC1100 Setup and Installaon
Inial Steps
Only qualied personnel should perform this installaon.
Turn the input power o at the disconnect switch or fuse box before working on the welder.
Do not touch electrically hot parts.
This secon provides detailed instrucons for the proper installaon of the TWE SC1100. It is
recommended that these instrucons be followed carefully to allow for the best possible oper-
ang environment.
Handling and Unpacking the Welder
Immediately upon receipt of the welder, inspect the shipment for any damage and nofy the
carrier of such damage before accepng delivery. Then inspect welder for damage which may
have occurred in transit. Aer 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 airow through the welder. If the
equipment is not being installed immediately, store it in a clean, dry, well-venlated area unl in-
stallaon.
Selecng a Locaon
The locaon of the power source should be carefully selected to ensure sasfactory and dependa-
ble service. Choose a locaon relavely 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 obstrucon.
Electrical Input Requirement
The welding power source is designed to be operated from three-phase, 60Hertz, AC power sup-
ply. Consult your local electrical ulity if you have any quesons on the electrical system at the
present installaon site. The SC1100 should be operated from a separate, fused or circuit-breaker
protected circuit.

9
SC1100 Setup and Installaon
Preparing the Unit for Primary Power
Only qualied personnel should perform this installaon.
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 connecons 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.
Aach 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 Installaon
Power / Ground Connecons
Electrical Input Requirement
The SC1100 is equipped with an Input Voltage Jumper Block so you can operate the unit from
dierent 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
operaon.
Ground Cable Connecon
The SC1100 is equipped with one ground cable connecon located on the front of the welder
Secure the ground cable to welder and connect the ground clamp to the work surface the.

11
SC1100 Setup and Installaon
Cable / Gas Connecons
Weld Cable Connecon
The SC1100 weld cable connecon is located on the front of the welder
Connect stud gun cable assembly directly to the SC1100.
Plug stud gun control cable plug into the connector on the front of welder.
Gas line connecon
When “gas shield” welding connect the gas line from the foot piece of the stud gun into the gas
ng on the front of the SC1100 by easy quick connect ng.

12
Stud Gun Setup
Stud Gun Setup
Each stud welding applicaon 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 aach 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 applicaon.
 Select the grip to t the ferrule which is provided with the stud to be welded.
Aer 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 sucient amount of the stud is inserted in the chuck so that the stud is
held rmly.
 Aach the ferrule to the ferrule grip.
 Plunge seng; 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).
 Posion this assembly so that the stud moves freely through the ferrule when you slide the
sha of the stud gun back and forth.

13
Stud Gun Setup
Li
Set the li 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 aach 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 retracon of the sha of the stud gun. This is designated as the Li.
The li seng should be about 3/32” for general welding applicaons and studs ranging in diameter
through 3/4" this adjustment should be suitable. For larger diameter studs and select applicaons
the li should be adjusted to approximately 1/8”.
Adjusng the li:
 Remove the back cap of the stud gun.
 Loosen the two socket set screws around the periphery of the li adjustment screw.
 To increase li rotate the li adjustment screw counter clockwise and to decrease li rotate
clockwise.
 With each turn check the li by actuang the stud gun unl the desired li is achieved.
 Tighten the socket set screws to hold the li adjustment screw in place to secure the selected
seng.
 Replace the back cap of the stud gun.
Rear Coil Yoke
Set Screw
Li Adjusng Screw
Gun Body

14
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 sha of the stud gun engages the damp-
ener.
Rotang the dampener cover counter clockwise increases the amount of free travel.

15
Stud Gun Setup
Aaching the stud gun to start welding
 Select the gun, control cable, and weld cable that is recommended for the specic type of
welder and the job.
 Aach 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-
necon 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 aach the ferrule to the ferrule grip.
 Place stud onto surface to be welded and press stud gun down unl ferrule is ush with the
welding surface.
 Trigger the gun and hold in place unl cycle is completed.
 Pull gun assembly straight up o of the welded stud.
 Do not depress trigger when removing gun from stud.
 Remove the ferrule by breaking it o and inspect the weld.
 Make proper adjustments as needed.

16
SC1100 Power Switch/Power On
The power switch for the SC1100 is located on the le front of the
front control panel. Turn the red dial clockwise to the horizontal
posion ( I ) indicator to turn the unit ON. Turn the dial to the ver-
cal posion ( O ) indicator to turn the unit OFF.
When the welder is turned on, the digital display will go through a
self-diagnosc check. This takes approximately 3 to 5 seconds, and
then the digital display will show the last me and current to
which the unit was set. This denotes that the unit is ready to go.
When connected to the welder, the stud gun will actuate 3 mes,
indicang that there is a good connecon.
SC1100 Diagnosc Lights
On the Control Panel, located below the digital display, is a row of diagnosc lights for the welder.
WELD - When the stud gun is triggered, this light comes on to indicate that the OCV is present at
the output terminals.
CONT– This light indicates that contact is being made between the work and the stud.
TRIG - When the stud gun is triggered, this light comes on to indicate that the trigger circuit is
funconing properly, and that the welding unit is receiving feedback from the stud gun.
DIAG - 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 funcon unl it is cooled.
SC1100 Operaons - Sengs

17
SC1100 Operaons - Sengs
Seng Welding Controls - Time and Current
The me and current controls are located on the front of the welder. The controls consist of a
Time Buon, Current Buon, Adjustment Dial, and a Fine/Coarse Switch. The digital display will
indicate the sengs chosen during setup.
When seng me or current, depress and hold down appropriate buon, and turn Adjustment
Dial clockwise or counter-clockwise to the correct seng on the digital display.
Use the Fine/Coarse Switch for seng the appropriate me or current - this will toggle between
10’s or 100’s of amps and 10th’s and 100th’s of a second.
To adjust gas purge me, hold both the TIME and AMPS buons and turn Adjustment Dial. The
seng is saved when the buons are released.

18
SC1100 Operaons - Sengs
There is a chart of approximate sengs for full-base diameter studs located on the top cover of
the SC1100.
Weld Counter and Weld Counter Reset
The SC1100 is equipped with dierent counters to display the number of mes the unit has drawn
an arc or the stud gun has been actuated.
Perpetual Weld Counter (Non-reseable) - This is a running total of every me an arc is drawn on
the machine. This is programmed from the factory and can not be reset.
Perpetual Gun Counter (Non-reseable) - This is a running total of every me the stud gun is
actuated whether an arc was drawn or not.
Job Counter (Reseable) - 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 posion. Each weld will
be recorded on the Current digital display. If the switch is in the Coarse posion, the weld will sll
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 posion.
To Reset the Job Counter;
1. Turn o unit.
2. Depress and hold down Time and Current buons.
3. Turn on machine.
4. Keep holding down buons unl OUTPUT light ashes then release the buons.
5. Job Counter will now be set at 0.
6. Weld count will now register on Current digital display.
SC1100 approximate me and current sengs

19
SC1100 Operaons - Sengs
SC1100 Supervisor Lock
The supervisor lock prevents the sengs from being adjusted. The purpose is to allow a meas-
ure of process control. All sengs and the counter may be viewed when the lock is acvated.
To acvate the lock, turn clockwise toward the 3 o’clock posion. To deacvate the lock, turn
counter-clockwise toward the 12 o’clock posion.

20
SC1100 Operaons - Welding
Stud Welding - Step by Step
The weld gun is posioned over the base material and the main gun spring
is parally compressed. Hold gun perpendicular to work surface and hold
ferrule rmly against the surface.
The trigger is pressed and the stud lis o 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
resulng 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 o 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 nished length required for the parcular applicaon, keep in mind
the reducon in length (burn-o) from stud welding operaons. TRU-WELD stud lengths are al-
ways given before weld.
Diameter of Stud Reducon in Length
1/4” thru 5/8” 1/8”