Pro-Weld CD-212P Operation Manual
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Pro-Weld CD-212P Operation Manual

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OPERATION/ MAINTENANCE
MANUAL

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Summary of Contents for Pro-Weld CD-212P

  • Page 1 OPERATION/ MAINTENANCE MANUAL...

  • Page 3: Table Of Contents

    WELDABLE MATERIAL COMBINATIONS 13.0 CAUSES OF POOR OR ERRATIC WELDS 14.0 TROUBLE SHOOTING POOR WELDS 15.0 ROUTINE WELDER MAINTENANCE 16.0 ASSEMBLY –CD-212 CONTROLLER 16,17 16.1 PC Board Assembly Drawing TROUBLE SHOOTING – ELECTRICAL 19,20 18.0 CHECK LIST CD-212P SYSTEM P.N. 100-0117...
  • Page 4 WEL D CD -2 1 2 P LIST OF FIGURES CD CONTACT PROCESS STRAIGHT POLARITY HOOK-UP REVERSE POLARITY HOOK-UP CUPHEAD PIN HOOK-UP FRONT PANEL LAYOUT STANDARD GUN SETUP COLLET PROTECTOR SETUP TEMPLATE ADAPTER GUN SETUP COLLET PROTECTOR/BLUNT LEG SETUP LIGHT DUTY CD GUN HOT WELD COLD WELD ARC BLOW...
  • Page 5 WEL D CD -2 1 2 P...
  • Page 6 WEL D CD -2 1 2 P...
  • Page 7 WEL D CD -2 1 2 P...
  • Page 8 WEL D CD -2 1 2 P...

  • Page 9: Introduction

    WEL D CD -2 1 2 P 1.0 INTRODUCTION 3.0 UNPACKING YOUR UNIT Your new stud welding equipment is carefully Upon receipt of your unit, place it as close as constructed of the finest components and materials possible to the point of installation before unpacking available.

  • Page 10: General Description

    WEL D CD -2 1 2 P 5. Don’t operate with worn or poorly con- The system comes complete with power cord, weld nected cables. Don’t operate weld gun with cables and gun. Just add the accessories required for loose cable connections. Inspect all cables fre- the stud size to be welded.

  • Page 11: Power Requirements

    WEL D CD -2 1 2 P This technique, when equipment is set up properly, Weld Mode: is simple and easily mastered. The same power sup- Contact ply is capable of welding many different sizes and Polarity: materials of fasteners. If you require assistance in Straight or Reverse selecting the proper accessories, contact our cus- Power Required:...

  • Page 12: Welding System Hook-Up

    WEL D CD -2 1 2 P 9.0 WELDING SYSTEM HOOK-UP 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).

  • Page 13: Reverse Polarity

    WEL D CD -2 1 2 P 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).

  • Page 14: Cuphead Pin Hook-Up

    WEL D CD -2 1 2 P 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).

  • Page 15: System Operation

    WEL D CD -2 1 2 P 10.0 SYSTEM OPERATION (see Figure 4) The CD-212 is designed for simple, yet precise operation. It has an “ON-OFF” rocker switch/indicator light (1) and a variable voltage control dial (2) on the front panel. Before turning the unit “ON”, the voltage control knob (2) should be turned counter-clockwise to the lowest setting.

  • Page 16: Gun Set-Up

    WEL D CD -2 1 2 P 11.0 GUN SET-UP For CD welding, the stud normally should be 11.1 STANDARD (see Figure 5) engaged for all but 1/4” of its length, whenever pos- sible. Selecting the proper stop will accomplish this The standard gun set-up is used for welding the for you.

  • Page 17: Installing Or Changing Collets Or Chucks

    WEL D CD -2 1 2 P The gun is now ready to weld. Select the 1. It does not require a pin stop. proper setting for the size stud to be welded. Voltage therefore, the same setup is applicable is determined by the weld base diameter.

  • Page 18: Template Adapter

    WEL D CD -2 1 2 P 11.4 TEMPLATE ADAPTER (see Figure 7) 11.5 COLLET PROTECTOR/BLUNT LEG (see Figure 8) The template adapter is used when precise location or positioning of the CD stud is required. The round faceplate, with blunt legs, can alter- It is used with the round faceplate and does not re- nately be used with the collet protector as shown in quire a footpiece or legs.
  • Page 19 WEL D CD -2 1 2 P PAGE INTENTIONALLY LEFT BLANK...

  • Page 20: Light Duty Cd Gun

    WEL D CD -2 1 2 P Figure 10 Light Duty CD Gun PAGE 11...
  • Page 21 WEL D CD -2 1 2 P 11.6 PARTS LIST LIGHT DUTY CD HANDGUN Part No. 300-0100 ITEM PART NO. DESCRIPTION 033-384 GUN (CD) REAR CAP MOLDED 001-800 SPRING MAIN HEAVY SILVER 033-610 GUN (CD/DA) BEARING ASSEMBLY 033-799 GUN (CD) SHAFT TUBE 033-016 HEX HEAD CAP SCREW 033-382...

  • Page 22: Weldable Material Combinations

    WEL D CD -2 1 2 P 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...

  • Page 23: Causes Of Poor Or Erratic Welds

    WEL D CD -2 1 2 P 13.0 CAUSE OF POOR OR ERRATIC 12. Incorrect spring. (REPLACE WITH PROPER WELDS SPRING) 1. Loose collet. Does not grip stud tightly. 13. Poor stud quality. (REPLACE) Not enough engagement of stud to col- let.

  • Page 24: Routine Welder Maintenance

    WEL D CD -2 1 2 P 15.0 ROUTINE WELDER MAINTENANCE Your CD-212 is designed for long service with minimum care. Ordinary common sense mainte- nance will keep it operating efficiently. 1. Treat the welding, ground, and control ca- bles with respect. Avoid sharp bends and kinks which Figure 13 Arc Blow may break the cables.

  • Page 25: Assembly -Cd-212 Controller

    WEL D CD -2 1 2 P 16.0 ASSEMBLY CD-212P CONTROLLER (see Figure 16,17, & 18) Figure 16 Parts List ITEM DESCRIPTION PART NUMBER Chassis 101-0030 SCR Mounting 124-0026 Main SCR 108-0001 Capacitor (3) 106-0023 Transformer 105-0017 PC Board 600-0013...
  • Page 26 WEL D CD -2 1 2 P Figure 17 Parts List ITEM DESCRIPTION PART NUMBER Knob 102-0060 Female Camlok (2) 107-0002 2-Pole Female Hubbell 107-0031 Power Switch 104-0013 Circuit Breaker 104-0020 Fan Guard 102-0039 PAGE 17...

  • Page 27: Pc Board Assembly Drawing

    WEL D CD -2 1 2 P 16.1 PC BOARD ASSEMBLY DRAWING FU1 and FU2 are 3AG 1 ampere fuses Figure 18 PC Board PAGE 18...

  • Page 28: Trouble Shooting - Electrical

    WEL D CD -2 1 2 P 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.
  • Page 29 WEL D CD -2 1 2 P 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.
  • Page 30 WEL D CD -2 1 2 P 18.0 CHECK LIST CD-212P SYSTEM PT. NO. 100-0117 STANDARD CD-212P WELDING SYSTEM COMPLETE WITH B-COLLET GUN AND 25’ #4 GROUND CABLE ITEM DESCRIPTION PART # CD-212P CONTROLLER 110 VAC 200-0025 GUN ASSY. B-COLLET w/INTEGRAL 25 FT.WELD &...
  • Page 32 MANUFACTURED BY WELD MADE IN THE U.S.A.

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