K.C.D. STUDWELDING CD1000 User manual

INSTRUCTION MANUAL
CD1000
PIN WELDER
K.C.D. STUDWELDING
96A Herald St, Cheltenham
Victoria 3192, Australia
Tel: [phone], Fax: [phone]
Email: [e-mail]
Web: www.kcdstudwelding.com.au

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
1
TABLE OF CONTENTS
Warranty………………………………………..……………………………….2
Safety Precautions……………………………………………………………….3
CD1000 Pin Welder Components……………..………………………………...4
Cable Connections for Welding Pins or Studs ………………………………….5
Pin Welder Gun…………………………………………………………………6
How To Use Your CD1000 Pin Welder……...…………………………………7
Appendix 1: Trouble Shooting Guide…………………………………...9
Appendix 2: Specifications……………………………………………...15

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
2
WARRANTY
The welding capacitors are fully guaranteed for a period of one hundred and twenty (120)
days from delivery date. In addition, all remaining parts used in the assembly of your
K.C.D. Studwelding Capacitor Discharge Stud Welding Systems are fully guaranteed for 12
months from delivery date.
If defects in material or workmanship occur during this period, K.C.D. Studwelding reserves
the right to repair or replace the defective parts. Notice of Claim must be furnished to the
manufacturer within ten (10) days after the defect is discovered. Return of the defective unit,
freight prepaid, and repair or replacement will be made at no charge to the purchaser.
K.C.D. Studwelding does not warrant defects in welders, parts or accessories resulting from
abuse, misuse, improper installation, or for reasons beyond its control.
The warranty may be void if the welding pins and/or studs used are not supplied by K.C.D.
Studwelding.

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
3
SAFETY PRECAUTIONS
Comply with all electrical and fire codes and ordinances in the installation and use of your
welding system. Remove any volatile materials and chemicals from welding area. Do not
weld in any area that might contain a volatile or explosive atmosphere.
1. It is recommended that eye protection be worn at all times when welding, and avoid
looking directly at the weld arc.
2. For complete protection, especially when welding vertical surfaces or overhead, a
jacket or apron and sleeves, gloves, and a hard hat are advisable.
3. Prevent sleeves, rings, watchbands, etc from coming into contact with gun shaft,
chuck, collet, pin/stud or welding surface.
4. Never stand in water or weld with damp or wet clothing on. Make sure that all parts
of the welding system are dry before proceeding to weld.
5. Be sure that cables and connectors are in good condition.
BUILT IN SAFETY MECHANISM
To ensure operator safety the CD1000 Pin Welders are fitted with a quick action Circuit
Breaker, which operates if a voltage above 30 volts is detected across the output terminals of
the welder. If such a voltage is detected, the Circuit Breaker / mains power switch will trip;
turning the machine off and discharging any voltage across the capacitor bank. However the
Circuit Breaker may also trip due to excessive vibration or knocking of the machine. If this is
the case then the machine can be immediately switched back on.
The gun body is fully insulated and the trigger voltage at the gun is only 16V DC.
IMPORTANT
As the capacitors within the machine have the potential to store extremely dangerous
voltages, with or without the power supply, therefore it is important that the machine and the
240V outlet are both turned off. It is also recommended that only qualified technicians
remove the cover to check inside the machine.

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
4
CD 1000 PIN WELDER COMPLETE SYSTEM
POWER UNIT & CONTROLLER
WELD GUN & CABLES EARTH CLAMP & CABLE
NOTE: Upon receipt of the CD1000 Pin Welder check to see that no damage has been caused
in transit and that the welding system is complete.

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
5
CABLE CONNECTIONS FOR WELDING PINS
NEGATIVE EARTH
Negative earth connections are recommended when:-
1. Pin welding to galvanised material.
2. Stud welding to plated surfaces.
3. When material to be welded is slightly rusty or mill scaled.
POSITIVE EARTH
Positive earth connections are recommended when:-
1. Welding pins to unplated surfaces.
NOTE: Do not coil cables as inconsistent welds can result.

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
6
PIN WELDER GUN
GUN SET UP FOR WELDING PINS
By using a nylon chuck guard, weld pins of various lengths may be used without any
adjustment to the gun head.
NOTE:
The nylon chuck guard must be floating freely on the chuck and must not be tightened onto
the gun shaft. This is because when the pin is forced down onto the work, the chuck guard
forces back onto the chuck, tightening the chuck closed on the weld pin. This produces less
burning on the pin and hence longer chuck life.

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
7
HOW TO USE YOUR CD1000 PIN WELDER
OPERATION
1. Uncoil the gun and earth cables. Attach the gun cables and earth cable to the stud
welding unit.
The earth cable with attached clamp is connected to the negative front panel
connector (marked negative). Make sure the plug is turned and locked into
position.
The gun weld cable is connected to the positive front panel connector (marked
positive). Make sure the plug is turned and locked into position.
The control cable is connected to the 4 pin front panel connector (marked control
cable). Make sure the plug is clicked correctly into position.
NOTE: This is a standard setting for welding onto galvanised sheet. If you have a
different application, refer to the recommended polarity on page 5.
2. Attach your earth cable to your material to be welded. Make sure the clamp is secured
tightly.
3. Plug your machine into a 240v outlet.
4. Turn the voltage control dial to zero. This control dial sets the capacitor voltage.
5. Turn your CD1000 on.
6. Turn the voltage control dial to setting 8. This is an average setting. We recommend
that you test fire some pins or studs to check that you are getting the required power.
Your CD1000 is now ready to use.
7. Insert the capacitor discharge (CD) pin into the gun. Push the pin in until it is flush
with the brass nozzle.

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
8
8. Put the gun to your work. With one hand on the back of the gun, keeping the pressure
downwards, use the other hand to press the trigger to weld.
9. Remove the gun from your work. It is important that when you lift the gun off the
work that you lift the gun straight up until the gun clears the pin. This ensures that
your welded pin is not bent when you take the gun off the work. It also ensures that the
copper chuck inside the gun does not get damaged. If the chuck becomes loose this can
cause burning between the pin and the chuck which is detrimental to the welding
process.
10. Insert another CD pin and repeat the process.
NOTE: Always make trial welds before starting on the work. You can then adjust voltages
and polarities as required.

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
9
APPENDIX 1:
TROUBLE SHOOTING GUIDE
THE FOLLOWING PAGES CONTAIN A QUICK REFERENCE GUIDE TO
COMPONENT IDENTIFICATION AND LOCATING SIMPLE PROBLEMS
THAN CAN EASILY BE FIXED BY A QUALIFIED TECHNICIAN.
IT IS HIGHLY RECOMENDED THAT ONLY
QUALIFIED TECHNICIANS REMOVE THE
COVER OF YOUR CD1000 WELDING UNIT AS
CAPACITORS IN THE MACHINE HAVE THE
POTIENTIAL TO STORE EXTREMELY
DANGEROUS HIGH VOLTAGES WITH OR
WITHOUT THE POWER SUPPLY CONNECTED.
THEREFORE IT IS IMPORTANT THAT THE
MACHINE AND THE 240V OUTLET ARE BOTH
TURNED OFF.
If you are not able to have a qualified technician look at the unit
should a fault occur, contact K.C.D. Studwelding for further advice.

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
10
COMPONENT IDENTIFICATION AND LOCATION GUIDE
Component I.D. Description Location
R1 Resistor 470R 2W metal film PCB
R2 Resistor 470R 1W metal film PCB
R3 Resistor 22K 3W metal film PCB
R4 Resistor 220R 2W metal film PCB
R5 N/A
R6 Resistor 47K 2W carbon film PCB
R7 Resistor 10R 3W metal film PCB
R8 N/A
R9 Resistor 220R 1W metal film PCB
R10 wire link PCB
R11 N/A
R12 wire link PCB
R13 Resistor 470R 1W metal film PCB
R14 Resistor 3K3 10W wire wound PCB
R15 N/A
R16 Resistor 47R 4W ceramic wire wound PCB
R17 Resistor 5R 100W wire wound Machine Base
R18 Resistor 100R 75W wire wound Machine Base
VR1 Trimpot 10K 10 turn PCB
VR2 Potentiometer 2K 3W Front Panel
C1 Capacitor 470uF 25volt electrolytic PCB
C2 Capacitor 47nF 400volt polyester PCB
C3 –C4 Capacitor 470uF 25volt electrolytic PCB
C5 –C8 Capacitor 8,000uF 175volt electrolytic Machine Base
D1 –D5 Rectifier diode 1N4004 PCB
D6 Zener Diode 10volt 1N5347B PCB
D7 N/A
D8 Rectifier diode 1N4004 PCB
D9 N/A
D10 Rectifier diode 1N4004 PCB
D11 N/A

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
11
COMPONENT IDENTIFICATION AND LOCATION GUIDE (cont.)
Component I.D. Description Location
D12 wire link PCB
D13 Zener Diode 12volt 1N5349 POS. Weld Terminal
D14 Zener Diode 12volt 1N5349B PCB
D15 Rectifier diode 1N4004 PCB
D16 Rectifier diode skn26/08 Capacitor Bank
Q1 N/A
Q2 –Q3 SCR 2N6399 sensitive gate 25amp PCB
Q4 NPN transistor 2n3904 PCB
Q5 PUT transistor 2N6027 PCB
Q6 N/A
Q7 SCR SKT 340/12E Machine Base
RLY1 Relay 12vDC 4PCO PCB
RLY2 Relay S1200 A240/0013 Machine Base
SW1 Gun trigger switch V-15-3C5 Weld Gun
CB1 Circuit Breaker on/off switch Front Panel

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
12
TROUBLE SHOOTING FOR CD1000 WELDERS
The following trouble shooting procedures are to aid in the quick location of machine faults.
In our experience we have found that 70% of machine breakdowns occur because of broken
wires within the trigger and weld cables. This is usually caused by people misusing the
equipment and dragging the machine along by the gun leads.
PROBLEM 1. WELDER DOES NOT TURN ‘ON’
(No red light on front panel)
Possible causes: 1. Blown Fuse.
Replace 7.5 amp and if the fuse does not blow again, check to see that
another fault, ie shorted weld capacitor (C5-C8), has not caused the
fault.
2. Faulty power lead.
Check for break in 240-volt supply cable. Usually breaks occur where
the cable enters the machine.
PROBLEM 2. WELDER TURNS ON (indicator lamp lights) BUT NO CHARGE
APPEARS ACROSS THE WELD CAPACITORS.
Possible causes. 1. Faulty relay RLY2.
If the relay RLY2 has failed to energise when the machine is switched
on, RLY1 will energise preventing weld capacitors to charge via Q3.
Change relay RLY2.
2. Faulty transformer.
An unusual fault but transformer secondary voltages should be
checked.
3. Open circuit or not switching on.
Check Q3 and also gate circuit components R14 and D5.
4. Faulty contact on relay RLY1 (RLY1/1)
Change relay if necessary.

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
13
PROBLEM 3. FUSE BLOWS EACH TIME WELDER IS TURNED ON.
Possible causes. 1. Shorted weld capacitors are not shorted or breaking down under
load.
2. Faulty SCR, Q3 in charging circuit.
Check that Q3 is not short-circuited.
3. Faulty Transformer.
Check that transformer has not burnt out.
PROBLEM 4. FUSE BLOWS WHEN WELD IS MADE.
Possible Causes 1. Faulty SCR, Q3 in charging circuit.
If Q3 is short-circuited and the AC applied to the electrolytic
capacitors did not blow the fuse; the fuse would certainly blow when
the weld was made.
2. Faulty Relay.
If contacts RLY1/1 were not opening when weld is made, fuse would
certainly blow.
PROBLEM 5. WELDER CHARGES UP BUT WILLNOT WELD.
(Broken wires in cables cause 70% of faults)
Possible causes. 1. Relay will not energise when trigger is pressed.
(a) Check that the chuck has not burnt out and that it is not making
contact with the weld pin / stud.
(b) Check for faulty trigger switch.
(c) Check D.C. output of bridge rectifier D1 to D4.
(d) Check for faulty relay contacts RLY1/2.
(e) Check for continuity of the gun weld cable, trigger cable and
earth cable. Breaks in either of these cables will cause the relay
not to energise.

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
14
2. Trigger is pressed; relay energises, but still no weld.
(a) Check for faulty relay. RLY1/4 not contacting properly.
(b) Check components in gate circuit of SCR, Q7.
(c) Check that SCR, Q7 has not open circuited.
PROBLEM 6. WELD EXCESSIVELY HOT REGARDLESS OF VOLTAGE
SETTING.
(No control of voltage across weld capacitors)
Possible Causes. 1. Potentiometer, VR2 on front panel open circuit.
2. Faulty SCR, Q2 trigger circuit.
3. Faulty SCR, Q3.
4. Resistors R3 or R6 open circuit.
PROBLEM 7. VOLTAGE PROTECTION CIRCUIT BREAKER / MAIN POWER
SWITCH TRIPS WHEN MACHINE IS TURNED ON.
Possible cause. 1. Faulty main weld SCR, Q7.

CD1000 Pin Welder Instruction Manual
K.C.D. Studwelding, Cheltenham, Victoria. Tel: [phone], Fax: [phone]
15
APPENDIX 2:
SPECIFICATIONS
STUD SIZE .105” insulation pin through 5/32 whit or M4 threaded studs
STUD MATERIAL Copper finished mild steel, stainless steel and brass studs.
Zinc plated and stainless steel pins.
WEIGHT 15 kg.
SIZE 315mm x 436mm x 245mm
WELDING RATE 15 per minute
INPUT POWER 240 V.A.C.
WELD MODE Contact
CIRCUIT
PROTECTION Primary fuses. Output voltage; circuit breaker operator protection.
CABLE LENGTH Gun 4.8m (16’)
Earth 3.04m (10’)
WELD GUN
WEIGHT 0.68 kg (1.5lbs)
SIZE 11.4 cm x 5 cm x 14.9 cm
MATERIAL High strength, impact resistant glass fibre reinforced polycarbonate.