OPERATION/ MAINTENANCE MANUAL
PRO WEL D CD -2 1 2 GAP 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 GENERAL 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 4 5 9.1 9.2 Straight Polarity Reverse Polarity 10.0 SYSTEM OPERATION 6 11.0 GUN SET-UP 7 7 8 8 9 9 10 11 12 13 15 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.
PRO WEL D CD -2 1 2 GAP LIST OF FIGURES 1 CD CONTACT PROCESS 2 2 STRAIGHT POLARITY HOOK-UP 4 3 REVERSE POLARITY HOOK-UP 5 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 14 10 HOT WELD 17 11 COLD WELD 17 12 ARC BLOW 18 13 WELD WITHOUT FOOTPIECE 18 14 GOOD WELD 18 15 PARTS LIST 19 16 PARTS LIST (continued) 20 17 PC BOARD 21
PRO WEL D CD -2 1 2 GAP
PRO WEL D CD -2 1 2 GAP
PRO WEL D CD -2 1 2 GAP
PRO WEL D CD -2 1 2 GAP
PRO WEL D 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 engineering advances, for completely reliable end welding of mild steel, stainless steel, aluminum and lead free copper and brass fasteners.
PRO WEL D 5. Don’t operate with worn or poorly connected cables. Don’t operate weld gun with loose cable connections. Inspect all cables frequently for insulation failures, exposed wires, loose connections, and repair as needed. 6. Don’t overload welding cables or continue to operate with hot cables. 7. Don’t weld near flammable materials or liquids, in or near atmospheres, or on ducts carrying explosive gases. 8.
PRO WEL D This technique, when equipment is set up properly, is simple and easily mastered. The same power supply is capable of welding many different sizes and materials of fasteners. If you require assistance in selecting the proper accessories, contact our customer service department or your field representative. 7.
PRO WEL D CD -2 1 2 GAP 9.0 WELDING SYSTEM HOOK-UP 9.1 Straight Polarity (Standard Set-Up) (see Figure 2) A. Connect ground cable connector (1A) into camlok (1). The camlok should be connected into the receptacle marked GROUND. 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) into the receptacle marked GUN (4). Twist clockwise until it locks. D.
PRO WEL D CD -2 1 2 GAP 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) into the receptacle marked GROUND (1). Twist clockwise until it locks. D.
PRO WEL D CD -2 1 2 GAP 10.0 SYSTEM OPERATION (see Figure 4) 1. The CD-212 is designed for simple, yet precise operation. 2. It has an “ON-OFF” rocker switch/indicator light (1) and a variable voltage control dial (2) on the front panel. 3. Before turning the unit “ON”, the voltage control knob (2) 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” position. The integral indicator light (1) will turn on.
PRO WEL D CD -2 1 2 GAP 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 consists 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 necessary to have the proper accessories for the stud to be welded.
PRO WEL D 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 diameter. 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.
PRO WEL D 11.4 TEMPLATE ADAPTER (see Figure 7) The template adapter is used when precise location or positioning of the CD stud is required. It is used with the round faceplate and does not require a footpiece or legs. The adapter is fastened to the faceplate and provides a fixed distance between the collet and work. The plunge is set by using the correct stop in the collet. A template can then be fabricated to enable very precise locating of a particular stud. CD -2 1 2 GAP 11.
PRO WEL D CD -2 1 2 GAP GAP GUN ITEM PART # QTY 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 F01358 M01797 F01377 M01375 F01376 F01372 M01329 F01368 F01369 F01370 F01366 F01367 F01381 M01328 M01325 F01383 F01382 M01532 M01386 3 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 6 21 F01371 1 Page 10 DESCRIPTION GROUNDING FOOT THREAD PIN M6X6 FOOT RING UNION NUT RUBBER BELLOW FINDER SLEEVE STRAIGHT PIN 3X8 WORKING PISTON FEATHER KEY RELEASE RING PISTOL SHELL LHS PISTOL SHELL RHS TRIGGER HANDLE STRAIGHT PIN
PRO WEL D CD -2 1 2 GAP Adjustment of stud welding gun Adjustment of stud collet 1. Stud 2. Collet 3. Counternut 4. Stop Screw For different stud diameters, different collets are required. Adjust collet as follows: * Loosen counternut (3) * Insert stud (1) into collet. The top edge of the stud flange must project for about .06 (1.5 mm) from the front edge of the collet. NOTE: The stud must make contact with the stop screw(4).
PRO WEL D CD -2 1 2 GAP Installation of stud collet into stud welding gun The illustration below shows how to install the stud collet into the stud welding 1. Tripod leg 2. Collet 3. Sleeve nut 4. Bellow 5. Gun shaft 6. Stud flange * Loosen sleeve nut (3) by means of a socket wrench. * Insert collet (2) into gun shaft (5) until stop * Tighten collet (2) with sleeve nut (3) NOTE: The stud flange must project from the top of the tripod legs for the thickness of the flange.
PRO WEL D CD -2 1 2 GAP Adjustment of spring pressure The pressure with which the stud is pressed against the workpiece during the welding process is called spring pressure. The following illustration shows how to adjust the spring pressure of stud welding gun which is equipped with a spring pressure indicator. 1. Adjusting screw 2. Spring pressure indicator The spring pressure is adjusted by means of the adjusting screw (1). The adjusted pressure is indicated at the spring pressure scale (2).
PRO WEL D Figure 9 Light Duty CD Gun Page 14 CD -2 1 2 GAP
PRO WEL D CD -2 1 2 GAP 11.6 PARTS LIST LIGHT DUTY CD HANDGUN Part No. 300-0100 ITEM PART NO. DESCRIPTION QTY 1 033-384 GUN (CD) REAR CAP MOLDED 1 2 001-800 SPRING MAIN HEAVY SILVER 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 SCREW SET MS, BRASS PLT 2 8 NOT USED GUN (CD/DA/FA) CABLE CLAMP (ALUM.
PRO WEL D CD -2 1 2 GAP 12.0 WELDABLE MATERIAL COMBINATIONS BASE MATERIAL STUD MATERIALS Mild Steel (1008-1018) Mild Steel 1008, 1018 Stainless Steel 304, 305 Brass 65-35, 70-30 Copper, Silicon/Bronze Galvanized Sheet (duct-”Q” Decking Mild Steel 1008-1018 Stainless 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 1100, 3000 and 5000 series.
PRO WEL D CD -2 1 2 GAP 13.0 CAUSE OF POOR OR ERRATIC WELDS 12. Incorrect spring. (REPLACE WITH PROPER SPRING) 1. Loose collet. Does not grip stud tightly. (REPLACE) Not enough engagement of stud to collet. (CHANGE STOP) 13. Poor stud quality. 2. Fault or loose ground connection. (REPAIR OR TIGHTEN) 14.0 TROUBLE SHOOTING POOR WELDS 3. Poor surface condition of base material, excessive oil, grease, rust, ect. (CLEAN) 4. Voltage or capacitance setting too low or too high.
PRO WEL D CD -2 1 2 GAP 15.0 ROUTINE WELDER MAINTENANCE Your CD-212 is designed for long service with minimum care. Ordinary common sense maintenance will keep it operating efficiently. Figure 12 Arc Blow Arc Blow A) Use double grounds. B) Ground too close or not spaced Figure 13 Weld without footpiece 1. Treat the welding, ground, and control cables with respect. Avoid sharp bends and kinks which may break the cables. Don’t use the cables as a “tow line” to move the control.
PRO WEL D CD -2 1 2 GAP 16.
PRO WEL D CD -2 1 2 GAP 18 14 17 16 15 Figure 16 Parts List (continued) ITEM 14 15 16 17 18 Page 20 DESCRIPTION Knob Female Camlok (2) 2-Pole Female Hubbell Power Switch Circuit Breaker PART NUMBER 102-0060 107-0002 107-0031 104-0013 104-0020
PRO WEL D CD -2 1 2 GAP V4 R23 C6 R20 + V5 R17 D6 R16 V3 R18 R12 D1 OP2 OP1 + C8 R26 R24 D9 C3 R9 V2 R4 D2 OP3 R25 R5 + D4 R22 V1 C1 C5 D5 R14 R21 ZD2 C7 D7 + R7 R8 R15 V6 R11 C2 C4 + R6 ZD1 R10 R13 16.
PRO WEL D CD -2 1 2 GAP 17.0 TROUBLE SHOOTING – ELECTRICAL When troubleshooting the power unit/controller (welder), the following precautions must be observed: 1. Welder must be TURNED OFF! 2. Unplug power cable from welder and wait at least two minutes before checking components. 3. The use of a volt/ohmmeter is recommended where any voltage may be present. 4. Use a continuity tester ( or troubleshooting light) for continuity checks only. 5.
PRO WEL D CD -2 1 2 GAP PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 3. Welder turns on but does not operate A. Ground cable connections not complete. Check for continuity *B. Broken gun control cable or loose wire connection in the plug. Shorted or open trigger switch. Check continuity between pins on control plug while trigger is depressed. Should read continuity. *C. Faulty printed circuit board. Replace with new PC Board. D. Shorted weld SCR.
PRO WEL D CD -2 1 2 GAP 18.0 CHECK LIST CD-212 SYSTEM PT. NO. 100-0112 STANDARD CD-212 WELDING SYSTEM COMPLETE WITH B-COLLET GUN AND 25’ #4 GROUND CABLE ITEM 1. 2. 3. 4. 5. DESCRIPTION PART # QTY CD-212 CONTROLLER 110 VAC GUN ASSY. B-COLLET w/INTEGRAL 25 FT.WELD & CONTROL CABLE 2-LEGS, and FOOTPIECE GROUND CABLE #4 X 15’ MANUAL, Operation and Maintenance CD-212 HEX WRENCH SET 200-0015 1 300-0100 125-0100 1 1 1 1 19.0 CHECK LIST CD-212 SYSTEM PT. NO.
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