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!
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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.

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
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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

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.



11

SC900SetupandInstallation
Cable/GasConnections

WeldCableConnection
TheSC900weldcableconnectionislocatedonthefrontofthewelder
ConnectstudguncableassemblydirectlytotheSC900.
Plugstudguncontrolcableplugintotheconnectoronthefrontofwelder.



Gaslineconnection
When“gasshield”weldingconnectthegaslinefromthefootpieceofthestudgunintothegas
fittingonthefrontoftheSC900byeasyquickconnectfitting.


12

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.

13

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

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shaftofthestudgunengagesthedamp‐
ener.
Rotatingthedampenercovercounterclockwiseincreasestheamountoffreetravel.

15

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.

16

SC900PowerSwitch/PowerOn
ThepowerswitchfortheSC900islocatedontheleftfrontofthe
frontcontrolpanel.Turnthereddialclockwisetothehorizontal
position(I)indicatortoturntheunitON.Turnthedialtothever‐
ticalposition(O)indicatortoturntheunitOFF.
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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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times,
indicatingthatthereisagoodconnection.
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SC900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.
SC900Operations‐Settings

17

SC900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.
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Whensettingtimeorcurrent,depressandholddownappropriatebutton,andturnAdjustment
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between
10’sor100’sofampsand10th’sand100th’sofasecond.
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Toadjustgaspurgetime,holdboththeTIMEandAMPSbuttonsandturnAdjustmentDial.The
settingissavedwhenthebuttonsarereleased.
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18
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SC900Operations‐Settings
Thereisachartofapproximatesettingsforfull‐basediameterstudslocatedonthetopcoverof
theSC900.
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WeldCounterandWeldCounterReset
TheSC900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.
SC900approximatetimeandcurrentsettings

19

SC900Operations‐Settings
SC900SupervisorLock
Thesupervisorlockpreventsthesettingsfrombeingadjusted.Thepurposeistoallowameas‐
ureofprocesscontrol.Allsettingsandthecountermaybeviewedwhenthelockisactivated.
Toactivatethelock,turnclockwisetowardthe3o’clockposition.Todeactivatethelock,turn
counter‐clockwisetowardthe12o’clockposition.

20
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SC900Operations‐Welding
StudWelding‐StepbyStep
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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.
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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.
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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.
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Theweldguniswithdrawnfromtheweldstudleavingandtheferrule.The
ferruleisbrokenawayanddiscarded.Visuallyinspectweld.
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***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”
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