Pro-Weld CD-312 User Manual
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Pro-Weld CD-312 User Manual

Pro-weld cd-312
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OPERATION/ MAINTENANCE
MANUAL

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  • Page 1 OPERATION/ MAINTENANCE MANUAL...

  • Page 3: Table Of Contents

    CAUSES OF POOR OR ERRATIC WELDS 14.0 TROUBLE SHOOTING POOR WELDS 15.0 ROUTINE WELDER MAINTENANCE 16.0 ASSEMBLY –CD-312 CONTROLLER 18,19,20 16.1 PC Board Assembly Drawing 17.0 TROUBLE SHOOTING – ELECTRICAL 18.0 CHECK LIST CD-312 SYSTEM P.N. 100-0108 19.0 CHECK LIST CD-312 SYSTEM P.N. 100-0109...

  • Page 4: List Of Figures

    WEL D CD -3 1 2 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 -3 1 2...
  • Page 6 WEL D CD -3 1 2...
  • Page 7 WEL D CD -3 1 2...
  • Page 8 WEL D CD -3 1 2...

  • Page 9: Introduction

    WEL D CD -3 1 2 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

    (SEE FIGURE 1). Verify that the gun is held perpendicular to the work. Pulling the trigger The CD-312 portable CD welder is a self con- discharges the capacitors through the stud which va- tained heavy duty capacitor discharge power supply porizes the tip.

  • Page 11: Power Requirements

    WEL D CD -3 1 2 This technique, when equipment is set up properly, Capacitance: is simple and easily mastered. The same power sup- 88,000 uF nominal ply is capable of welding many different sizes and Weld Mode: materials of fasteners. If you require assistance in Contact selecting the proper accessories, contact our cus- Polarity:...

  • Page 12: Welding System Hook-Up

    WEL D CD -3 1 2 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 -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).

  • Page 14: Cuphead Pin Hook-Up

    WEL D CD -3 1 2 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

    10.0 SYSTEM OPERATION (see Figure 4) The CD-312 is designed for simple, yet precise operation. 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.
  • Page 16 WEL D CD -3 1 2 Setting the Weld Voltage/Capacitance The voltage charge on the capacitor bank is read on the digital panel meter. The ready light indicates Slowly turn the voltage control knob when the capacitors are charged and a stud may be clockwise to increase the weld voltage until the welded.

  • Page 17: Gun Set-Up

    WEL D CD -3 1 2 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 18: Installing Or Changing Collets Or Chucks

    WEL D CD -3 1 2 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. Be sure for a range of pin lengths.

  • Page 19: Template Adapter

    WEL D CD -3 1 2 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 20: Light Duty Cd Gun

    WEL D CD -3 1 2 Figure 10 Light Duty CD Gun PAGE 12...
  • Page 21 WEL D CD -3 1 2 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 -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...

  • Page 23: Causes Of Poor Or Erratic Welds

    WEL D CD -3 1 2 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 -3 1 2 15.0 ROUTINE WELDER MAINTENANCE Your CD-312 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-312 Controller

    WEL D CD -3 1 2 16.0 ASSEMBLY CD-312 CONTROLLER (see Figure 15,16, & 17) Figure 16 Parts List ITEM DESCRIPTION PART NUMBER Knob 102-0060 Charge Pot 25K 111-0001 SCR Mounting 124-0026 Main SCR 108-0001 Buss Bar 124-0037 Buss Bar...
  • Page 26 WEL D CD -3 1 2 Figure 17 Parts List ITEM DESCRIPTION PART NUMBER Terminal Strip 102-0020 Transformer 105-0010 Dropping Resistor 112-0042 Discharge Resistor 112-0041 Nichrome Resistor 112-0043 PC Board 600-0007 Charging SCR 108-0002 Diode 108-0027 Charging Bridge 108-0017 Safety Discharge SCR 108-0042 PAGE 18...
  • Page 27 WEL D CD -3 1 2 Figure 18 Parts List ITEM DESCRIPTION PART NUMBER Power Switch 104-0013 LED Panel Meter 103-0002 LED Red 108-0028 LED Green 108-0029 LED Amber 108-0030 2-Pole Female Hubbell 107-0031 Female Camlok 107-0002 PAGE 19...

  • Page 28: Pc Board Assembly Drawing

    WEL D CD -3 1 2 16.1 PC BOARD ASSEMBLY DRAWING FU2 and FU3 are 3AG 1 ampere fuses Figure 19 PC Board PAGE 20...

  • Page 29: Trouble Shooting - Electrical

    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.
  • Page 30 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.
  • Page 31 GROUND CABLE #4 X 15’ 125-0100 MANUAL, Operation and Maintenance CD-312 HEX WRENCH SET 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 #...
  • Page 34 MANUFACTURED BY WELD MADE IN THE U.S.A.

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