Pro-Weld CD-512 User manual

OPERATION/MAINTENANCE
MANUAL

CD-512
PRO WELD
TABLE OF CONTENTS
1.0 INTRODUCTION 1
2.0 WARRANTY 1
3.0 UNPACKING YOUR UNIT 1
4.0 SUGGESTED SAFETY PRECAUTIONS 1
5.0 GENERA L DESCRIPTION 2
6.0 THE CD WELDING PROCESS 2
7.0 POWER REQUIREMENTS 3
8.0 SYSTEM SPECIFICATIONS 3
9.0 WELDING SYSTEM HOOK - UP 4
9.1 Straight Polarity 4
9.2 Reverse Polarity 5
10.0 SYSTEM OPERATION 6
11.0 GUN SET - UP 8
11.1 Standard 8
11.2 Installin g or Changing Collets or Chucks 9
11.3 For Weld Pins with Collet Protector 9
11.4 Template Adapter 10
11.5 Collet Protector w ith Blunt Leg 10
11.6 Parts List HD CD Handgun 12
12.0 WELDABLE MATERIAL COMBINATIONS 13
13.0 CAUSES OF POOR OR ERRATIC WELDS 14
14.0 TROUBLE SHOOTING POOR WELDS 14
15.0 ROUTINE WELDER MAINTENANCE 15
16.0 ASSEMBLY – CD - 512 CONTROLLER 16,17,18
16.1 PC Board Assembly Drawing 19
17.0 TROUBLE SHOOTING – ELECTRICAL 20
18.0 CHECK LIST CD - 512 SYSTEM P.N. 100 - 0110 22
19.0 CHECK LI ST CD - 512 SYSTEM P.N. 100 - 0111 22

CD-512
PRO WELD
LIST OF FIGURES
1 CD CONTACT PROCESS 2
2 STRAIGHT POLARITY HOOK- UP 4
3 REVERSE POLARITY HOOK - UP 5
5 FRONT PANEL LAYOUT 6
6 STANDARD GUN SETUP 8
7 COLLET PROTECTOR SETUP 9
8 TEMPLATE ADAPTER GUN SETUP 10
9 COLLET PROTECTOR/BLUNT LEG SETUP 10
10 HEA VY DUTY CD GUN 11
11 HOT WELD 14
12 COLD WELD 14
13 ARC BLOW 15
14 WELD WITHOUT FOOTPIECE 15
15 GOOD WELD 15
16 PARTS LIST 16
17 PARTS LIST (continued) 17
18 PARTS LIST (continued) 18
19 PC BOARD 19

CD-512
PRO WELD

CD-512
PRO WELD

CD-512
PRO WELD

CD-512
PRO WELD

CD-512
PRO WELD
1 .0 INTRODUCTION
Your new stud welding equipment is carefully
constructed of the finest components and materials
available. Used properly, this equipment will give
you years of profitable, efficient service.
The system incorporates the latest in enginee r-
ing advances, for completely reliable end welding of
mild steel, stainless steel, aluminum and lead free
copper and brass fasten ers.
A careful study of this manual will enable you
to understand how the welder operates to insure
proper performance under al l operating conditions.
2.0 WARRANTY
The electrical and mechanical components of
the stud welder are thoroughly performance i n-
spected prior to assembly in the welder. The asse m-
bled welder is completely performance checked. The
welder is delivered to you in functional electro -
mechanical condition.
All p arts used in the assembly of the welder
and its accessories are fully warranted for a period of
1 YEAR from the date of delivery . In addition, the
welding capacitors are warranted for a period of 1
YEAR from the date of delivery. The printed circuit
boards used in all proweld equipment are warranted
for a period of 3 years.
Under the warranty, the manufacturer reserves
the right to repair or replace, at their option, defe c-
tive parts which fail during the guarantee period.
No tice of any claim for warranty repair or replac e-
ment must be furnished to the manufacturer by the
pu r chaser within ten (10) days after the defect is first
discovered. The manufacturer does not assume any
liability for paying shipping cost or any labor or m a-
terials furnished where such cost are not expressly
authorized in writing.
The manufacturer does not warrant any parts or
acces sories against failures resulting from misuse,
abuse, improper installation, maladjustment, or use
not in accordance with the operating instructions fu r-
nished by the manufacturer. The warranty is valid
only when studs are purchased from sources a p-
proved by the manufacturer or are of identical spec i-
fi cations to the manufacturer’s
3 .0 UNPACKING YOUR UNIT
Upon receipt of your unit, place it as close as
possible to the point of installation before unpacking
it. Do not operate the unit from an extension power
cord if possible. Once the unit is unpacked it is reco m-
mended that you inspect it for any physical damage.
Your unit has been completely assembled and
inspected at the factory. Upon receipt, the unit must be
hooked up to the recommended incoming power b e-
fore welding. We recommend that you check that you
have received all the items listed on the shipping
check list. (see SECTION 1 8 or 19)
Place the unit in a large enough area to provide
adequate ventilation. Do not restrict the air flow
through the side l ouvers. Do not allow water to enter
the control housing.
4.0 SUGGESTED SAFETY PRECA U-
TIONS
In any welding operation, it is the responsibi l-
ity of the welder to observe certain safety rules to i n-
sure his personal safety and to protect those working
near him.
Reference is directed, without endorsement or
recommendation, t o ANSI Z49.1, Safety in Welding
and Cutting, and to AWG Publication A6,1 - 66, Re c-
om mended Safety Practices for Gas - Shield Arc Wel d-
ing.
1. Always treat electricity with respect. Under
open circuit conditions, the welding machine
output voltage may be dang erous.
2. Don’t work on live circuits or conductors.
Disconnect the main power line before check -
ing the machine or perform ing any mainte -
nance operations.
3. Be sure the welding machine cabinet is
properly grounded to a good electrical ground.
4. Don’t stand in water or on a damp floor
while welding or weld in the rain. Avoid wear-
ing wet sweaty cloths when welding.
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CD-512
PRO WELD
5. Don’t operate with worn or poorly con -
nected cables. Don’t operate weld gun with
loose cable connections. Inspect all cable s fre -
quently for insulation failures, exposed wires,
loose connections, and repair as needed.
6. Don’t overload welding cab les or continue
to operate with hot cables.
7. Don’t weld near flammable materials or liq -
uids, in or near atmospheres, or o n ducts carry -
ing explosive gases.
8. Don’t weld on containers which have held
combustible or flammable materials, or on ma -
terials which give off flammable or toxic va -
pors when heated, without proper cleaning,
purging, or inerting.
9. Be sure t o provide for proper ventilation
when welding in confined spaces.
10. Never look at the electric arc without wear -
ing protec tive eye shields.
11. Always use the proper protective clothing,
gloves, ect.
12. Never strike an arc when near a bystander
who is unaware of the dangers of ultraviolet
light on their eyes.
5.0 GENERAL DESCRIPTION
CD - 512 HEAVY DUTY PORTABLE
CD ST UD/PIN WELDER
The CD - 512 portable CD welder is a self co n-
tained heavy duty capacitor discharge power supply
capable of welding up to 5/16” flanged studs in mild
steel or stainless steel (3/8” in weld base diameter).
It can weld up to 1/4 flanged studs (5/16” weld base
diameter) in aluminum or brass.
The CD -512 utilizes a solid state control board
for longer life and has been designed for easy mai n-
te nance and field service. This welder uses standard
1 10 volt AC line voltage. The system comes complete
with power cord, weld cables and gun. Just add the
accessories required for t he stud size to be welded.
This manual should provide all the information r e-
quired for you to be able to set up, weld, and maintain
the CD - 512 welding system.
6.0 THE CD WELDING PROCESS
Contact welding is the simplest and most
co m mon method of CD stud welding. Practically
foo l proof, it produces no reverse side marking in
most cases and is suitable for most commercial and
industrial applications.
First , the gun must be set -up with the proper
accessories for the length and diameter stud you are
going to weld. Refer to the CD Acc essories Guide
and CD Stud Welding Gun Section for information
on accessories and gun set -up.
Initial Contact During Weld
Forced Into Molten Pool After Weld
1 2
3 4
The stud is first placed in contact with the
base material (SEE FIGURE 1). Verify that the gun is
held perpendicular to the work . Pulling the trigger
di scharges the capacitors through the stud which v a-
porizes the tip. The proper tip design is critical. This
is what determines the length of time of the weld. An
arc is briefly sustained which melts the stud base su r-
face and the work surface directly underneath the
stud. The spring pressure in the gun then forces the
stud into the molten pool, completing the weld in a p-
proximately six milliseconds.
(FIGURE 1 CONTACT CD WELD)
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CD-512
PRO WELD
T his technique, when equipment is set up properly,
is simple and easily mastered. The same power su p-
ply is capable of welding many different sizes and
materials of fasteners. If you require assistance in
selecting the proper accessories, contact our cu s-
tomer service department or your field represent a-
tive.
7.0 POWER REQUIREMENTS
110 VOLT OPERATION
110 volt AC 60 H: 25 amp service
Internal Fusing : BUSS ABC 25 amps;
slo w blow;
P/N 120 -0025
Integral 9 foot power cord
IF EXTENSION REQUIRED
Cable Length 110 Volt
12’ #16/3
25’ #16/3
30’ #14/3
50 #12/3
8.0 SYSTEM SPECIFICATIONS
Weight:
64 Lbs.
Size:
8 1/2” H x 13 1/4” W x 20” D
21.6 cm H x 33.7 cm W x 50.8 cm D
Chassis:
16 Ga. Steel (Painted International Orange)
Panel Controls:
Power
Voltage Control
Weldable Materials:
Steel, Stainless steel, Aluminum, Copper,
Brass, Zinc coated, Galvanized
Weldable Stud Diameter:
12 Ga. Through 7/16” Weld Ba se
(Max W.B. Dia. For AL=5/16” {1/4” thread})
Weld Rate:
24 per minute 5/16”
Weld Voltage:
45- 185 VDC
Capacitance:
84,000 uF nominal Low Range
168,000 uF nominal High Range
Weld Mode:
Contact
Polarity:
Straight or Reverse
Powe r Required:
110 Volt AC 60 Hz 25 Amp
Internal Fusing:
BUSS ABC 25 Amp Slo - Blow(110V)
3AG 1 Amp 250 volt (2 on PC board)
STAN DARD GUN & CABLE SPECIFICATIONS
WELD GUN - LIGHT DUTY PRECISION
CD CONTACT
Part Number:
300- 0200 HD B Collet Gun
300- 0201 HD Taper Tip Gun
Weight:
2 lbs. (not including cable)
( lbs. (including 25 ft. #4 weld cable & 16 -4
SOW control cable)
Size:
6 1/2” x 5 3/4” x 2”
Weldable Stud Diameter:
12 Ga. Through 7/16” W.B. Dia.
Material:
High strength, impact resistant, glass fi ber re -
inforced polycarbonate
Integral Gun Cable Length:
25 feet – #1 AWG
Connectors:
Male Camlok / 2 Pin Hubbell Male
Cable s
Ground Cable:
(2) #1 x 15’ (P/N: 125 - 0101)
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CD-512
PRO WELD
9.0 WELDING SYSTEM HOOK - UP
9.1 Straight Polarity (Standard Set - Up) (see Figure 2(shown with dual grounds))
A. Connect ground ca ble connector (1A) into camlok (1). The camlok should be connected into the
receptacle marked GROUND. Twist until it locks. Atta ch “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 wel ding cables are coiled.
Figure 2 Straight Polarity Hook - Up
1
1
1A
1A
5 2
4A
3
4
3A
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CD-512
PRO WELD
9.2 Reverse Polarity (Recommended for brass or galvanized) (see Figure 3)
A. Connect ground cable connector (1A) into camlok ( 4). The camlok should be connected into the
receptacle marked GUN. Twist until it locks. Attach “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) in to the receptacle marked GROUND (1). Twist clockwise until
it locks.
D. Connect AC power cable to AC outlet.
NOTE:
The gun wel ding and control cables must be laid out in a straight line. Poor weld quality may
result if welding cables are coiled.
Figure 3 Reverse Polarity Hook - Up
4A 4
1A
1
3
3A
2 5
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CD-512
PRO WELD
1 0.0 SYSTEM OPERATION
(see Figure 4)
1. The CD - 512 is designed for simple, yet precise operation.
2. It has an “ON - OFF” toggle switch/indicator light (1) a High/Low range selection switch (2),a
variable voltage control dial (3) a ready indicator light (4 ), a contact light (5) and a trigger light (6) on
the front panel.
3. Before turning the unit “ON”, the voltage control knob (3 ) should be turned counter - clockwise
to the lowest setting.
4. With all cables connected, turn the unit on by putting the rocker switch (1) in the “ON” pos i-
tion. The integral indicator light (1) will turn on.
5. When the capacitors reach the charge voltage setting, the ready light ( 4) will turn on.
Figure 5 Front Panel Layout
4
6 5
1 2 3
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CD-512
PRO WELD
S etting the Weld Voltage/Capacitance
Slowly turn the voltage control knob
clockwise to increase the weld voltage until the
indi cator knob is pointing at the appropriate
number for the particular stud size that you are
welding. (See the set up information chart).
NOTE:
Once the voltage control knob is set to
a higher setting, turning it counter- clockwise
will NOT reduce the volta ge on the capacitor
bank, until the toggle switch (1) is turned
“OFF” (for approximately 10 seconds).
The settings are marked with the vol t-
ages corresponding to various stud sizes. The
approximate voltages for each stud size is as
follows:
LOW RANGE
45 – 60 VDC Min.
65 – 95 VDC 12 ga.
95 – 120 VDC #8
120 – 145 VDC #10
145 – 180 VDC 1/4”
180 – 185VDC MAX.
HIGH RANGE
60 – 100 VDC 1/4”
100 – 140 VDC 5/16”
140 – 170 VDC 3/8”
The voltage charge on the capacitor bank is read on
the digital panel meter. The ready light indicates
when the capacitors are charged and a stud may be
welded.
Contact Light
The contact light indicates there is an a c-
cep t able electrical connection between the stud and
ground. This light will turn on when the stud is
placed in contact with the ground.
Trigger Light
The trigger light indicates there is a co m-
plete circuit to the unit through the gun control c a-
ble and switch. This light will turn on when the gun
trigger is pressed.
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CD-512
PRO WELD
For CD welding, the stud normally should be
engaged for all but 1/4” of its length, whenever po s-
si ble. Selecting the proper stop will accomplish this
for you. The objective of the collet is to maintain a
firm grip on the faste ner to assure correct alignment
and a good electrical connection, yet allow for ease
of loading.
Once the selection of the cor rect accessory is
made, assembly may begin. The footpiece is
mounted on the legs using 10 - 32 x 3/4” socket head
cap screws, inse rted through the holes at the base of
the footpiece. These holes are recessed so that the
head of the screws will not protrude.
After assembling the legs and footpiece, insert
the collet and stop into the open end of the gun shaft.
Secure the collet in p lace with two set screws on the
shaft. Locate the legs, with footpiece attached, in the
Figure 6 Standard Gun Setup
11.0 GUN SET - UP
11.1 STANDARD (see Figure 5)
The standard gun set - up is used for welding the
majority of applications. It co nsists of the 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 necessar y to
have the proper accessories for the stud to be
welded. Those required are the legs, footpiece,
spring, collet, and appropri ate screws and washers.
A 3/32” and a 5/32” hex wrench are the only tools
needed for the adjustment of the gun.
h oles provided in the gun faceplate. (It
may be necessary to back off the
socket screw in the faceplate to allow
the legs to ente r the hole). Center the
opening of the footpiece around the
weld end of the fastener. Tighten the
footpiece in position at this time. A d-
justment for the plunge which is the
distance the stud protrudes beyond the
end of the footpiece can now be made.
This is done b y loosening the two 10 -
32 x 1/4” set screws at the bottom of
the faceplate using the 3/32” Allen
wrench. Then sliding the legs f or
proper adjustment. Refer to the set -up
chart for correct plunge distance (from
1/8” to 5/16”).
NOTE:
Correct set - up on all CD units is
1/8” - 5/16” plunge. This must be a s-
sured for proper weld results in all
cases.
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CD-512
PRO WELD
Figure 7 Collet Protector Gun Setup
The gun is now ready to weld. Select the
proper setting for the size stud to be welded. Voltage
is determined by the weld base d iameter. Be sure
your power source is set for the proper polarity:
straight for steel, reverse for galvanized.
11.2 INSTALLING OR CHANGING COLLETS
OR CHUCKS
( The terms collet or chuck are different names for
the same device). The collet holds the pin or stud to
be welded. It is secured to the gun shaft by two set
screws. These screws are loosened to remove or r e-
place a collet. Tighten these screws snugly to secure
the collet in place.
When you change the size of the stud you are
weldin g, you must also change to the appropriate
co l let. If a collet becomes damaged or broken, 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 two standard sizes available: 12 ga.
And 10 ga. It is used with the round faceplate and
three blunt legs. The collet protector slides over the
coll et and fastens to the chuck with three allen set
screws. The insert, which takes the place of the I n-
teral stop, is replaceable.
The stud is pushed into the chuck until the flange bo t-
toms out on the insert. The collet protector is not
available for studs larger than 10 ga.
The standard adjustable legs and footpiece
combination can alternately be used with the collet
protector as shown in Figure 7.
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CD-512
PRO WELD
1 1.4 TEMPLATE ADAPTER (see Figure 7)
The template adapter is used when precise
location or positioning of the CD stud is requir ed.
It is used with the round faceplate and does not r e-
quire a footpiece or legs. The adapter is fastened to
the faceplate and provides a fixed distance b e-
tween the collet and work. The plunge is set by u s-
ing the correct stop in the collet. A template can
then be fabricated to enable very precise locating
of a particular stud.
Th e template adapter is available in two
sizes, (1” and 1 - 1/4” diameter).
1 1.5 COLLET PROTECTOR/BLUNT LEG
(see Figure 8)
The round faceplate, with blunt legs, can alte r-
nately be used with the collet protector as shown in
Figure 8.
Figure 8 Template Adapter gun setup
Figure 9 Collet Protector/Blunt Leg Setup
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CD-512
PRO WELD
Figure 10 Heavy Duty CD Gun
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CD-512
PRO WELD
11.6 PARTS LIST LIGHT DUTY CD HANDGUN
Part No. 300-0100
ITEM PART NO. DESCRIPTION QTY
1 033-384 GUN (CD) REAR CAP MOLD ED 1
2 001-801 SPRING MAIN HEAVY BLACK 1
3 033-610 GUN (CD/DA) BEARING ASSEMBLY 1
4 033-799 GUN (CD) SHAFT TUBE 1
5 033-016 HEX HEAD CAP SCREW 3
6 033-382 GUN (CD/DA/FA) TRIGGER SPRING 1
7 049-955 M SCR EW SET MS, BRASS PLT 2
8 NOT USED GUN (CD/DA/FA) CABLE CLAMP (ALUM. BLOCK) 1
9 033-404 TRIGGER SWITCH 1
10 033-381 GUN (CD/DA/FA) TRIGGER BUTTON MOLDED 1
11 036 - 496HD GUN (FL) SHAFT BLOCK – A 1
12 033 - 662 - 25HD 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 - HD GUN (CD) WELD PIGTAIL A SSY 1
20 018-375 SCREW PAN HEAD 2
21 016-876 WASHED, LOCK INTO. TOOTH 1
22 033-757 LEG (CD) STD.ADJ . 7” 2 REF.
23 009-929 FLAT WASHER 2 REF.
24 016-378 SOCKET HEAD CAP SCREW 2 REF.
25 028-833 STD. FOOTPIECE 1 REF.
PAGE 12