Pro-Weld CD-212 Operation & Maintenance Manual
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Pro-Weld CD-212 Operation & Maintenance Manual

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OPERATION/ MAINTENANCE
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Summary of Contents for Pro-Weld CD-212

  • Page 1 OPERATION/ MAINTENANCE MANUAL...

  • Page 3: Table Of Contents

    CAUSES OF POOR OR ERRATIC WELDS 13.0 TROUBLE SHOOTING POOR WELDS 14.0 ROUTINE WELDER MAINTENANCE 15.0 ASSEMBLY –CD-212 CONTROLLER 16.0 15,16 16.1 PC Board Assembly Drawing TROUBLE SHOOTING – ELECTRICAL CHECK LIST CD-212 SYSTEM P.N. 100-0112 18.0 CHECK LIST CD-212 SYSTEM P.N. 100-0113 19.0...

  • Page 4: List Of Figures

    WEL D CD -2 1 2 LIST OF FIGURES CD CONTACT PROCESS STRAIGHT POLARITY HOOK-UP REVERSE POLARITY 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 WELD WITHOUT FOOTPIECE...
  • Page 5 WEL D CD -2 1 2...
  • Page 6 WEL D CD -2 1 2...
  • Page 7 WEL D CD -2 1 2...
  • Page 8 WEL D CD -2 1 2...

  • Page 9: Introduction

    WEL D CD -2 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

    CD-212 welding sys- tem. 6. Don’t overload welding cables or continue to operate with hot cables.

  • Page 11: Power Requirements

    WEL D CD -2 1 2 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 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 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: System Operation

    CD -2 1 2 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 15: Gun Set-Up

    WEL D CD -2 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 16: Installing Or Changing Collets Or Chucks

    WEL D CD -2 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 17: Template Adapter

    WEL D CD -2 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 18: Light Duty Cd Gun

    WEL D CD -2 1 2 Figure 9 Light Duty CD Gun Page 10...

  • Page 19: Parts List Ld Cd Handgun

    WEL D CD -2 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 20: Weldable Material Combinations

    WEL D CD -2 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 21: Causes Of Poor Or Erratic Welds

    WEL D CD -2 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 22: Routine Welder Maintenance

    WEL D CD -2 1 2 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 12 Arc Blow may break the cables.

  • Page 23: Assembly -Cd-212 Controller

    WEL D CD -2 1 2 16.0 ASSEMBLY CD-212 CONTROLLER (see Figure 15,16, & 17) Figure 15 Parts List ITEM DESCRIPTION PART NUMBER Chassis 101-0025 SCR Mounting 124-0026 Main SCR 108-0001 Capacitor (3) 106-0023 Transformer 105-0017 PC Board 600-0013 Discharge Resistor...
  • Page 24 WEL D CD -2 1 2 Figure 16 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 Page 16...

  • Page 25: Pc Board Assembly Drawing

    WEL D CD -2 1 2 16.1 PC BOARD ASSEMBLY DRAWING FU1 and FU2 are 3AG 1 ampere fuses Figure 17 PC Board Page 17...

  • Page 26: Trouble Shooting - Electrical

    WEL D CD -2 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 27 WEL D CD -2 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 28: Check List Cd-212 System P.n. 100-0112

    GROUND CABLE #4 X 15’ 125-0100 MANUAL, Operation and Maintenance CD-212 HEX WRENCH SET 19.0 CHECK LIST CD-212 SYSTEM PT. NO. 100-0113 STANDARD CD-212 WELDING SYSTEM COMPLETE WITH TAPER TIP GUN AND 25’ #4 GROUND CABLE ITEM DESCRIPTION PART #...
  • Page 30 MANUFACTURED BY WELD MADE IN THE U.S.A.

This manual is also suitable for:

Cd-212 gap

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