Pro-Weld CD-212, Operation & Maintenance Manual

Page 1: ...OPERATION MAINTENANCE MANUAL ...

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Page 3: ... 7 11 1 Standard 7 11 2 Installing or Changing Collets or Chucks 8 11 3 For Weld Pins with Collet Protector 8 11 4 Template Adapter 9 11 5 Collet Protector with Blunt Leg 9 11 6 Parts List LD CD Handgun 11 12 0 WELDABLE MATERIAL COMBINATIONS 12 13 0 CAUSES OF POOR OR ERRATIC WELDS 13 14 0 TROUBLE SHOOTING POOR WELDS 13 15 0 ROUTINE WELDER MAINTENANCE 14 16 0 ASSEMBLY CD 212 CONTROLLER 15 16 16 1 P...

Page 4: ... 4 FRONT PANEL LAYOUT 6 5 STANDARD GUN SETUP 7 6 COLLET PROTECTOR SETUP 8 7 TEMPLATE ADAPTER GUN SETUP 9 8 COLLET PROTECTOR BLUNT LEG SETUP 9 9 LIGHT DUTY CD GUN 10 10 HOT WELD 13 11 COLD WELD 13 12 ARC BLOW 14 13 WELD WITHOUT FOOTPIECE 14 14 GOOD WELD 14 15 PARTS LIST 15 16 PARTS LIST continued 16 17 PC BOARD 17 ...

Page 5: ...CD 212 PRO WELD ...

Page 6: ...CD 212 PRO WELD ...

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Page 8: ...CD 212 PRO WELD ...

Page 9: ...g from misuse abuse improper installation maladjustment or use not in accordance with the operating instructions fur nished by the manufacturer The warranty is valid only when studs are purchased from sources ap proved by the manufacturer or are of identical speci fications to the manufacturer s 3 0 UNPACKING YOUR UNIT Upon receipt of your unit place it as close as possible to the point of install...

Page 10: ... tenance and field service This welder uses standard 110 volt AC line voltage The system comes complete with power cord weld cables and gun Just add the accessories required for the stud size to be welded This manual should pro vide all the information required for you to be able to set up weld and maintain the CD 212 welding sys tem 6 0 THE CD WELDING PROCESS Contact welding is the simplest and m...

Page 11: ...ols Power Voltage Controls Weldable Materials Steel Stainless steel Aluminum Copper Brass Zinc coated Galvanized Weldable Stud Diameter 14 Ga Through 1 4 Flanged Max W B Dia For AL 5 16 1 4 thread Weld Rate 12 per minute Weld Voltage 45 200 VDC Weld Mode Contact Polarity Straight or Reverse Power Required 110 Volt AC 60 Hz 20 Amp Circuit Protection 15 Amp circuit breaker 3AG 1 Amp 250 volt fuses 2...

Page 12: ...h C clamp 2 to the workpiece 5 CLEANED AREA B Connect the gun control cable 3A into the female receptacle 3 C Connect the gun weld cable 4A into the receptacle marked GUN 4 Twist clockwise until it locks D Connect AC power cable to AC outlet NOTE The gun welding and control cables must be laid out in a straight line Poor weld quality may result if welding cables are coiled 3 3A 1 4 4A 1A 5 2 Figur...

Page 13: ...amp 2 to the workpiece 5 CLEANED AREA B Connect the gun control cable 3A into the female receptacle 3 C Connect the gun weld cable 4A into the receptacle marked GROUND 1 Twist clockwise until it locks D Connect AC power cable to AC outlet NOTE The gun welding and control cables must be laid out in a straight line Poor weld quality may result if welding cables are coiled 3 3A 1 4 4A 1A 5 2 Figure 3...

Page 14: ... Setting the Weld Voltage Capacitance Slowly turn the voltage control knob clockwise to increase the weld voltage until the indicator knob is pointing at the appropriate number for the particular stud size that you are welding See the set up information chart Below NOTE Once the voltage control knob is set to a higher setting turning it counter clockwise will NOT reduce the voltage on the capacito...

Page 15: ... standard adjustable face plate two legs a foot B collet stop and spring for your specific stud size A step by step explanation of the correct way to set up and operate the standard CD gun To prepare for stud welding it is necessary to have the proper accessories for the stud to be welded Those required are the legs footpiece spring collet and appropriate screws and washers A 3 32 and a 5 32 hex w...

Page 16: ...ken it must be replaced You may also need a stop 11 3 GUN SET UP FOR WELD PINS WITH COLLET PROTECTOR see Figure 6 The collet protector has several advantages over the standard set up 1 It does not require a pin stop therefore the same setup is applicable for a range of pin lengths 2 There is a fixed plunge no gun adjustments necessary 3 It provides stability at the weld end of the pin There are tw...

Page 17: ...stance be tween the collet and work The plunge is set by us ing the correct stop in the collet A template can then be fabricated to enable very precise locating of a particular stud The template adapter is available in two sizes 1 and 1 1 4 diameter 11 5 COLLET PROTECTOR BLUNT LEG see Figure 8 The round faceplate with blunt legs can alter nately be used with the collet protector as shown in Figure...

Page 18: ...CD 212 PRO WELD Figure 9 Light Duty CD Gun Page 10 ...

Page 19: ...CH 1 10 033 381 GUN CD DA FA TRIGGER BUTTON MOLDED 1 11 036 496 GUN FL SHAFT BLOCK A 1 12 033 662 25 GUN WELD CABLE 25 FT 1 13 033 658 25 GUN CONTROL CABLE 25 FT 1 14 033 881 GUN BODY RH LH STD CD MACHINED 1 15 033 445 GUN CD FL SHAFT BOOT ASSY 1 16 033 447 GUN CD SHAFT BOOT RETAINING RING 1 17 033 665 GUN CD FACEPLATE STD ADJUSTABLE 1 18 033 446 GUN CD SHAFT BOOT SNAP RING 1 19 033 608 GUN CD WEL...

Page 20: ...s Steel 304 305 Structural Steel Must Be Clean Mild Steel 1008 1018 Stainless Steel 304 305 Brass 65 35 70 30 Aluminum Most alloys of the Aluminum 1100 5356 1100 3000 and 5000 series Zinc Alloys Die Cast Aluminum 1100 5356 Medium Carbon Steel 1030 1018 Mild Steel 1008 1018 Stainless Steel 304 305 Brass 65 35 70 30 Lead Free Brass Mild Steel 1008 1018 Lead Free Rolled Brass Stainless Steel 304 305 ...

Page 21: ...ile the opposite side is gouged out or appears excessively hot The principle cause of arc blow is magnetic field induced by the current flow during the weld It occurs most often on long nar row strips of metal or near edges of sheets or plates In some cases a change in grounding positions or two grounds on the work piece one at each end or edge of work will correct the problem For assis tance in s...

Page 22: ...ter the gun or at the connec tors 2 It is good practice to occasionally remove the cover of the controller and clean with air and a soft brush around the components CAUTION Be sure the controller is disconnected from the power before removing the pro tective cover 3 While the cover is removed tighten all the weld cable connections and make sure all the screws on the capacitor terminals are torque ...

Page 23: ...r 105 0017 6 PC Board 600 0013 7 Discharge Resistor 112 0041 8 Safety Discharge SCR 108 0042 9 Charging SCR 108 0002 10 Buss Bar 124 0034 11 Diode 108 0027 12 Charging Bridge 108 0017 13 Buss Bar 124 0035 13a 150K 2 Watt 111 0002 1 2 3 4 5 6 7 9 10 11 12 13 8 Figure 15 Parts List 16 0 ASSEMBLY CD 212 CONTROLLER see Figure 15 16 17 Page 15 13a ...

Page 24: ...O WELD 16 14 15 18 17 Figure 16 Parts List ITEM DESCRIPTION PART NUMBER 14 Knob 102 0060 15 Female Camlok 2 107 0002 16 2 Pole Female Hubbell 107 0031 17 Power Switch 104 0013 18 Circuit Breaker 104 0020 Page 16 ...

Page 25: ...U2 are 3AG 1 ampere fuses Figure 17 PC Board D12 D13 D11 D10 V2 V3 R2 D3 R3 R12 R9 R11 R7 V1 R5 R4 D2 D1 OP2 D4 D5 C5 C2 V4 ZD1 R10 R8 R17 D6 R16 R18 OP3 R26 R19 D8 R1 R24 OP1 V5 ZD2 R14 D7 R15 C6 C3 D9 C8 R25 R22 R21 C4 R23 V6 R6 R20 R13 F2 F1 C7 C1 Page 17 ...

Page 26: ...e most common problems PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 1 Welder does not turn on A Power connections at Check connections and will not weld Welder or 110 VAC outlet not complete B Broken power cable or Check wires for continuity loose wire connection in Repair break the plug C Fuse blown Replace fuse 2 Fuse blows each time A Shorted weld capacitor Check safety vent seal for unit is turned...

Page 27: ...ier module if shorted 4 Weld is excessively hot A Shorted charge SCR Check with ohmmeter regardless of voltage should not show continuity setting In either direction Replace if shorted B Faulty printed circuit Replace with new PC board Board C Open voltage Replace defective voltage potentiometer Potentiometer 5 Poor and erratic A Improper gun setup Check applicable gun setup welding Instruction pa...

Page 28: ... 0100 1 3 GROUND CABLE 4 X 15 125 0100 1 4 MANUAL Operation and Maintenance CD 212 1 5 HEX WRENCH SET 1 19 0 CHECK LIST CD 212 SYSTEM PT NO 100 0113 STANDARD CD 212 WELDING SYSTEM COMPLETE WITH TAPER TIP GUN AND 25 4 GROUND CABLE ITEM DESCRIPTION PART QTY 1 CD 212 CONTROLLER 110 VAC 200 0015 1 2 GUN ASSY TAPER TIP w INTEGRAL 25 FT WELD CONTROL CABLE 2 LEGS and FOOTPIECE 300 0101 1 3 GROUND CABLE 4...

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Page 30: ...WELD PRO MANUFACTURED BY MADE IN THE U S A ...