Pro-Weld CD-312 Specifications

Add to my manuals
34 Pages

advertisement

Pro-Weld CD-312 Specifications | Manualzz

OPERATION/ MAINTENANCE

MANUAL

PRO WEL D

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

9.1 Straight Polarity 4

9.2 Reverse Polarity 5

9.3 Cuphead Pin 6

10.0 SYSTEM OPERATION 7

11.0 GUN SET-UP 9

11.1 Standard 9

11.2 Installing or Changing Collets or Chucks 10

11.3 For Weld Pins with Collet Protector 10

11.4 Template Adapter 11

11.5 Collet Protector with Blunt Leg 11

11.6 Parts List LD CD Handgun 14

12.0 WELDABLE MATERIAL COMBINATIONS 15

13.0 CAUSES OF POOR OR ERRATIC WELDS 16

14.0 TROUBLE SHOOTING POOR WELDS 16

15.0 ROUTINE WELDER MAINTENANCE 17

16.0 ASSEMBLY –CD-312 CONTROLLER 18,19,20

16.1 PC Board Assembly Drawing 21

17.0 TROUBLE SHOOTING – ELECTRICAL 22

18.0 CHECK LIST CD-312 SYSTEM P.N. 100-0108 24

19.0 CHECK LIST CD-312 SYSTEM P.N. 100-0109 24

CD -3 1 2

PRO WEL D

LIST OF FIGURES

1 CD CONTACT PROCESS 2

2 STRAIGHT POLARITY HOOK-UP 4

3 REVERSE POLARITY HOOK-UP 5

4 CUPHEAD PIN HOOK-UP 6

5 FRONT PANEL LAYOUT 7

6 STANDARD GUN SETUP 9

7 COLLET PROTECTOR SETUP 10

8 TEMPLATE ADAPTER GUN SETUP 11

9 COLLET PROTECTOR/BLUNT LEG SETUP 11

10 LIGHT DUTY CD GUN 13

11 HOT WELD 16

12 COLD WELD 16

13 ARC BLOW 17

14 WELD WITHOUT FOOTPIECE 17

15 GOOD WELD 17

16 PARTS LIST 18

17 PARTS LIST (continued) 19

18 PARTS LIST (continued) 20

19 PC BOARD 21

CD -3 1 2

PRO WEL D CD -3 1 2

PRO WEL D CD -3 1 2

PRO WEL D CD -3 1 2

PRO WEL D CD -3 1 2

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.

A careful study of this manual will enable you to understand how the welder operates to insure proper performance under all operating conditions.

2.0 WARRANTY

The electrical and mechanical components of the stud welder are thoroughly performance inspected prior to assembly in the welder. The assembled welder is completely performance checked. The welder is delivered to you in functional electromechanical condition.

All parts 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, defective parts which fail during the guarantee period.

Notice of any claim for warranty repair or replacement must be furnished to the manufacturer by the purchaser 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 materials furnished where such cost are not expressly authorized in writing.

The manufacturer does not warrant any parts or accessories against failures resulting from misuse, abuse, improper installation, maladjustment, or use not in accordance with the operating instructions furnished by the manufacturer. The warranty is valid only when studs are purchased from sources approved by the manufacturer or are of identical specifications to the manufacturer’s

CD -3 1 2

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 recommended 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 before welding. We recommend that you check that you have received all the items listed on the shipping check list. (see SECTION 18 or 19)

Place the unit in a large enough area to provide adequate ventilation. Do not restrict the air flow through the side louvers. Do not allow water to enter the control housing.

4.0 SUGGESTED SAFETY PRECAU-

TIONS

In any welding operation, it is the responsibility of the welder to observe certain safety rules to insure his personal safety and to protect those working near him.

Reference is directed, without endorsement or recommendation, to ANSI Z49.1, Safety in Welding and Cutting, and to AWG Publication A6,1-66, Recommended Safety Practices for Gas-Shield Arc Welding.

1. Always treat electricity with respect. Under

open circuit conditions, the welding machine

output voltage may be dangerous.

2. Don’t work on live circuits or conductors.

Disconnect the main power line before check-

ing the machine or performing 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.

PAGE 1

PRO WEL D

5. Don’t operate with worn or poorly con-

nected cables. Don’t operate weld gun with

loose cable connections. Inspect all cables fre-

quently 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 liq-

uids, in or near atmospheres, or on 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 to provide for proper ventilation

when welding in confined spaces.

10. Never look at the electric arc without wear-

ing protective 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-312 HEAVY DUTY PORTABLE

CD STUD/PIN WELDER

The CD-312 portable CD welder is a self contained 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-312 utilizes a solid state control board for longer life and has been designed for easy maintenance and field service. This welder uses standard

CD -3 1 2

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 provide all the information required for you to be able to set up, weld, and maintain the CD-312 welding system.

6.0 THE CD WELDING PROCESS

Contact welding is the simplest and most common method of CD stud welding. Practically foolproof, 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 Accessories Guide and CD Stud Welding Gun Section for information on accessories and gun set-up.

1

3

Initial Contact During Weld

2

4

Forced Into Molten Pool After Weld

(FIGURE 1 CONTACT CD WELD)

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 discharges the capacitors through the stud which vaporizes 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 surface 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 approximately six milliseconds.

PAGE 2

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.

7.0 POWER REQUIREMENTS

110 VOLT OPERATION

110 volt AC 60 H: 25 amp service

Internal : 20 amp;

circuit breaker (P/N: 104-0021)

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:

48 Lbs.

Size:

8 1/2” W x 10” D x 16 1/2” H

21.6 cm W x 25.4 cm D x 42 cm H

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 3/8” Weld Base

(Max W.B. Dia. For AL=5/16” {1/4” thread})

Weld Rate:

24 per minute 5/16”

Weld Voltage:

45-185 VDC

CD -3 1 2

Capacitance:

88,000 uF nominal

Weld Mode:

Contact

Polarity:

Straight or Reverse

Power Required:

110 Volt AC 60 Hz 25 Amp

Internal Fusing:

20 Amp Circuit Breaker

3AG 1 Amp 250 volt (2 on PC board)

STANDARD GUN & CABLE SPECIFICATIONS

WELD GUN-LIGHT DUTY PRECISION

CD CONTACT

Part Number:

300-0100 B Collet Gun

300-0101 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:

14 Ga. Through 1/4” Flanged

Material:

High strength, impact resistant, glass fiber re-

inforced polycarbonate

Integral Gun Cable Length:

25 feet – #4 AWG

Connectors:

Male Camlok / 2 Pin Hubbell Male

Cables

Ground Cable:

(1) #4 x 15’ (P/N: 125-0100)

PAGE 3

PRO WEL D CD -3 1 2

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. 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

4

4A

1

1A

2

5

Figure 2 Straight Polarity Hook-Up

PAGE 4

PRO WEL D CD -3 1 2

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. 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

1A

4

4A

2

5

Figure 3 Reverse Polarity Hook-Up

PAGE 5

PRO WEL D CD -3 1 2

9.3 Cuphead and Power Point pin hook-up (see Figure 4)

A. Connect ground cable connector (1A) into camlok (1). The camlok should be connected into the receptacle marked CUPHEAD. 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. 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 4

4A

1

1A

2

5

Figure 4 Cuphead Pin Hook-Up

PAGE 6

PRO WEL D CD -3 1 2

10.0 SYSTEM OPERATION

(see Figure 4)

1. The CD-312 is designed for simple, yet precise operation.

2. It has an “ON-OFF” toggle switch/indicator light (1) and a variable voltage control dial (2), a ready indicator light (3), a contact light (4) and a trigger light (5) 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.

5. When the capacitors reach the charge voltage setting, the ready light (4) will turn on.

2

1

4

3

5

Figure 5 Front Panel Layout

PAGE 7

PRO WEL D

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).

NOTE:

Once the voltage control knob is set to a higher setting, turning it counter-clockwise will NOT reduce the voltage on the capacitor bank, until the toggle switch (1) is turned

“OFF” (for approximately 10 seconds).

The settings are marked with the voltages corresponding to various stud sizes. The approximate voltages for each stud size is as follows:

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.

CD -3 1 2

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 acceptable 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 complete circuit to the unit through the gun control cable and switch. This light will turn on when the gun trigger is pressed.

PAGE 8

PRO WEL D CD -3 1 2

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. Those required are the legs, footpiece, spring, collet, and appropriate screws and washers.

A 3/32” and a 5/32” hex wrench are the only tools needed for the adjustment of the gun.

Figure 6 Standard Gun Setup

For CD welding, the stud normally should be engaged for all but 1/4” of its length, whenever possible. Selecting the proper stop will accomplish this for you. The objective of the collet is to maintain a firm grip on the fastener to assure correct alignment and a good electrical connection, yet allow for ease of loading.

Once the selection of the correct accessory is made, assembly may begin. The footpiece is mounted on the legs using 10-32 x 3/4” socket head cap screws, inserted 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 place with two set screws on the shaft. Locate the legs, with footpiece attached, in the holes provided in the gun faceplate. (It may be necessary to back off the socket screw in the faceplate to allow the legs to enter the hole). Center the opening of the footpiece around the weld end of the fastener. Tighten the footpiece in position at this time. Adjustment for the plunge which is the distance the stud protrudes beyond the end of the footpiece can now be made.

This is done by 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 for 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 assured for proper weld results in all cases.

PAGE 9

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. These screws are loosened to remove or replace a collet. Tighten these screws snugly to secure the collet in place.

When you change the size of the stud you are welding, you must also change to the appropriate collet. 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.

CD -3 1 2

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 collet and fastens to the chuck with three allen set screws. The insert, which takes the place of the Interal stop, is replaceable.

The stud is pushed into the chuck until the flange bottoms 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.

PAGE 10

Figure 7 Collet Protector Gun Setup

PRO WEL D CD -3 1 2

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.

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 alternately be used with the collet protector as shown in

Figure 8.

Figure 9 Collet Protector/Blunt Leg Setup

Figure 8 Template Adapter gun setup

PAGE 11

PRO WEL D CD -3 1 2

PAGE 12

Figure 10 Light Duty CD Gun

PRO WEL D

11.6 PARTS LIST LIGHT DUTY CD HANDGUN

Part No. 300-0100

CD -3 1 2

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. BLOCK) 1

9 033-404 TRIGGER SWITCH 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) WELD PIGTAIL ASSY 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 13

PRO WEL D CD -3 1 2

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 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

Electrolytic Copper Copper, Silicon/Bronze

PAGE 14

PRO WEL D

13.0 CAUSE OF POOR OR ERRATIC

WELDS

1. Loose collet. Does not grip stud tightly.

(REPLACE) Not enough engagement of stud to collet. (CHANGE STOP)

2. Fault or loose ground connection. (REPAIR OR

TIGHTEN)

3. Poor surface condition of base material, excessive oil, grease, rust, ect. (CLEAN)

4. Voltage or capacitance setting too low or too high.

(ADJUST TO DIAMETER OF STUD)

5. Broken or loose cables. (REPAIR)

6. Dirt in gun. (CLEAN)

7. Incorrect polarity. (CABLES HOOKED-UP

WRONG)

8. Use of center punch or deep scribe. (DO NOT

USE CENTER PUNCH OR DEEP SCRIBES)

9. Cables too closely coiled.

10. Arc blow is evidenced by “one side” welds. In severe cases there will be no melting under one edge of flange while 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, narrow 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 assistance in severe cases, contact your local sales representative.

11. Incorrect plunge setting. (ADJUST TO PROPER

SETTING)

CD -3 1 2

12. Incorrect spring. (REPLACE WITH PROPER

SPRING)

13. Poor stud quality.

14.0 TROUBLE SHOOTING POOR

WELDS

Figure 11 Weld too Hot

Weld too Hot

A) Decrease voltage.

B) Decrease capacitance.

C) Increase stud protrusion.

D) Increase spring pressure.

Figure 12 Weld too Cold

Weld too Cold

A) Increase voltage.

B) Increase capacitance.

C) Decrease stud protrusion.

D) Decrease spring pressure.

PAGE 15

PRO WEL D

Figure 13 Arc Blow

Arc Blow

A) Use double grounds.

B) Ground too close or not spaced

CD -3 1 2

15.0 ROUTINE WELDER

MAINTENANCE

Your CD-312 is designed for long service with minimum care. Ordinary common sense maintenance will keep it operating efficiently.

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. Avoid damage or straining the cables where they enter the gun or at the connectors.

2. It is good practice to occasionally remove the cover of the controller and clean with air and a soft brush around the components.

Figure 14 Weld without footpiece

Weld without footpiece

A) Use standard footpiece.

B) Use template adapter.

C) Use tripod blunt legs.

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 to 30 inchpounds.

NOTE:

Keep the gun free of dust, dirt or foreign material

Figure 15 Good Weld

PAGE 16

PRO WEL D

16.0 ASSEMBLY CD-312 CONTROLLER (see Figure 15,16, & 17)

CD -3 1 2

1A

1

2

3

4

5

Figure 16 Parts List

6

ITEM DESCRIPTION PART NUMBER

1 Knob 102-0060

1A Charge Pot 25K 111-0001

2 SCR Mounting 124-0026

3 Main SCR 108-0001

4 Buss Bar 124-0037

5 Buss Bar 124-0036

6 Capacitor 106-0023

7 Chassis 101-0016

7

PAGE 17

PRO WEL D

14

15

16

17

CD -3 1 2

8

9

11

10

Figure 17 Parts List

12

13

ITEM DESCRIPTION PART NUMBER

8 Terminal Strip 102-0020

9 Transformer 105-0010

10 Dropping Resistor 112-0042

11 Discharge Resistor 112-0041

12 Nichrome Resistor 112-0043

13 PC Board 600-0007

14 Charging SCR 108-0002

15 Diode 108-0027

16 Charging Bridge 108-0017

17 Safety Discharge SCR 108-0042

PAGE 18

PRO WEL D

19

18

CD -3 1 2

20

21

22

23

24

Figure 18 Parts List

ITEM DESCRIPTION PART NUMBER

18 Power Switch 104-0013

19 LED Panel Meter 103-0002

20 LED Red 108-0028

21 LED Green 108-0029

22 LED Amber 108-0030

23 2-Pole Female Hubbell 107-0031

24 Female Camlok 107-0002

PAGE 19

PRO WEL D

16.1 PC BOARD ASSEMBLY DRAWING

FU2 and FU3 are 3AG 1 ampere fuses

R34

D11

R30

R25

R17

R44

R16

R18

R28

R27

D10

+

+

R12

R11

R31

ZD4

+

C9

R20

R26

R19

D13

R23

R40

R37

R36

D21

D16

D23

R41

R22

ZD3

R6

R32

ZD5

R35

D22

D2

R5

D1

R9

D9

R8

D18

D17

R7

R15

D7

D6

R3

R1

R2

D8

ZD2

ZD1

R39

+

D20

D19

CD -3 1 2

Figure 19 PC Board

PAGE 20

PRO WEL D CD -3 1 2

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. Possible causes marked with a star (*) are generally the 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 on. Rupture hole. Replace

defective capacitor.

B. Shorted rectifier (BR1) Check for a short across the

rectifier with ohmmeter.

Replace rectifier module if

shorted.

C. Incorrect primary hookup. Check transformer connections.

D. Shorted transformer Replace transformer.

assembly.

PAGE 21

PRO WEL D CD -3 1 2

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

3. Welder turns on but A. Ground cable connections Check for continuity

does not operate not complete.

*B. Broken gun control cable Check continuity between

or loose wire connection pins on control plug while

in the plug. Shorted or trigger is depressed.

open trigger switch. Should read continuity.

*C. Faulty printed circuit Replace with new PC

board. Board.

D. Shorted weld SCR. Check with ohmmeter

(should not show continuity

in either direction). Replace

rectifier 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 page.

B. Improper grounding or Check applicable cable setup

cable setup or incorrect Instruction page.

polarity.

C. Weld cables are coiled. Straighten out cables.

D. Incorrect voltage setting. Adjust as necessary.

E. Studs or pins not Adjust legs as necessary.

perpendicular to work Replace defective legs.

surface.

PAGE 22

PRO WEL D CD -3 1 2

18.0 CHECK LIST CD-312 SYSTEM PT. NO. 100-0108

STANDARD CD-312 WELDING SYSTEM COMPLETE WITH B-COLLET GUN

AND 25’ #4 GROUND CABLE

ITEM DESCRIPTION PART # QTY

1. CD-312 CONTROLLER 110 VAC 200-0012 1

2. GUN ASSY. B-COLLET w/INTEGRAL 25 FT.WELD

& CONTROL CABLE 2-LEGS, and FOOTPIECE 300-0100 1

3. GROUND CABLE #4 X 15’ 125-0100 1

4. MANUAL, Operation and Maintenance CD-312 1

5. HEX WRENCH SET 1

19.0 CHECK LIST CD-312 SYSTEM PT. NO. 100-0109

STANDARD CD-312 WELDING SYSTEM COMPLETE WITH TAPER TIP GUN

AND 25’ #4 GROUND CABLE

ITEM DESCRIPTION PART # QTY

1. CD-312 CONTROLLER 110 VAC 200-0012 1

2. GUN ASSY. TAPER TIP w/INTEGRAL 25 FT.WELD

& CONTROL CABLE 2-LEGS, and FOOTPIECE 300-0101 1

3. GROUND CABLE #4 X 15’ 125-0100 1

4. MANUAL, Operation and Maintenance CD-312 1

5. HEX WRENCH SET 1

PAGE 23

MANUFACTURED BY

PRO WELD

MADE IN THE U.S.A.

advertisement

Was this manual useful for you? Yes No
Thank you for your participation!

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project

Questions and Answers

What is the maximum stud diameter that can be welded with the Pro-Weld CD-312?
The Pro-Weld CD-312 can weld studs up to 3/8" weld base diameter in mild steel or stainless steel (5/16" flanged studs), and up to 1/4 flanged studs (5/16" weld base diameter) in aluminum or brass.
What type of welding process does the Pro-Weld CD-312 use?
The Pro-Weld CD-312 uses the contact welding process, which is a simple and common method of CD stud welding. It produces no reverse side marking in most cases and is suitable for most commercial and industrial applications.
What is the power requirement for the Pro-Weld CD-312?
The Pro-Weld CD-312 requires 110 Volt AC 60 Hz 25 Amp power with an internal 20 Amp circuit breaker and a 9-foot power cord.
What is the weight and size of the Pro-Weld CD-312?
The Pro-Weld CD-312 weighs 48 Lbs. and measures 8 1/2" W x 10" D x 16 1/2" H (21.6 cm W x 25.4 cm D x 42 cm H).
What materials can be welded with the Pro-Weld CD-312?
The Pro-Weld CD-312 can weld mild steel, stainless steel, aluminum, copper, brass, zinc-coated, and galvanized materials.

Related manuals

Download PDF

advertisement