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MIDWEST FASTENERS CD 100 Owner's Manual

Solid state capacitor discharge stud welding system
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CD 100
Solid State
Capacitor Discharge
Stud Welding System
Ownerʼs Manual

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Summary of Contents for MIDWEST FASTENERS CD 100

  • Page 1 CD 100 Solid State Capacitor Discharge Stud Welding System Ownerʼs Manual...
  • Page 2 CD 100 Solid State Capacitor Discharge Stud Welding System Owner’s Manual • Installation • Operation • Maintenance CD 50 Stud Welder...
  • Page 3 ©2001 MIDWEST FASTENERS, INC., all rights reserved. 450 Richard Street Miamisburg, OH 45342 Phone: (800) 852-8352 Fax: (937) 866-4174 CD 50 Stud Welder...

  • Page 4: Table Of Contents

    Troubleshooting ................15 MAINTENANCE CD 100 Welder Specifications ............. 18 TROUBLESHOOTING CD 100 Welder Exploded View & Parts List ....... 19 SPECIFICATIONS CD 2P Gun Specifications ............20 CD 2P Gun Exploded View & Parts List ........21 CD 100 Electrical Schematic ............22...

  • Page 5: Warranty

    WARRANTY All parts used in the assembly of your MIDWEST FASTENERS Capacitor Discharge Stud Welding System are fully guaranteed for one (1) year from factory shipment date. Under this warranty, MIDWEST FASTENERS reserves the right to repair or replace, at its option, defects in material or workmanship which occur during the warranty period.

  • Page 6: Safety Precautions

    If possible, turn all power controls “OFF” and disconnect all electrical cables. For other suggested precautions, safe practices, etc. regarding welding, refer to “Safety in Welding and Cutting”, ANSI Z49.1, American National Standards Institute. — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 7: What Is Stud Welding

    The equipment required to stud weld is composed of a direct current power supply, a controller, a weld gun and cables to tie the system components together. In most systems the power supply and controller are combined into one unit called the “Welder.” CD 100 STUD WELDING SYSTEM (P/N: CDSW-100-01) Controller CDSW-100-00...
  • Page 8 2. Stud is lifted by weld gun and weld gun trigger depressed and initiating arc is drawn 3. Weld gun forces stud 4. Weld solidifies and into molten metal ferrule is removed — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 9: Cd 100 Overview

    OVERVIEW – CD 100 The CD 100 is a capacitor discharge stud welder. The weld energy is stored in capacitors located inside the control unit. The amount of stored energy CAPACITOR DISCHARGE can be controlled by rotating the voltage control knob located on the front STUD WELDER panel.

  • Page 10: Cd 100 Installation

    CD 100 INSTALLATION Follow the process below to properly install your CD 100 stud welder. CD 100 Cable Connections (straight polarity shown) Weld Controller Ground Cable (2 recommended) CONTROL NOTE: All cables should be laid out straight or in large loops.

  • Page 11: Cd 100 Setup

    • Insulation Pins with Internal Stop (Figure 2) • Weld Studs (Figure 3) • Weld Studs with Template Adaptor (Figure 4) NOTE: These components may need to be readjusted, or changed, as your job requirements change. — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 12: Insulation Pins

    1. Seat weld pin firmly against internal stop. 2. Loosen these adjustment screws. 3. Slide the Leg / Foot assembly until weld pin flange extends 1/8"- 3/16" beyond foot (or spark shield.) 4. Retighten adjustment screw. (Fig.2) — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 13: Weld Studs

    Adaptor Stud Adaptor Faceplate Faceplate 1/8"- 3/16" Protrusion Template Adaptors are used when precise positioning of the stud is required. (Observe correct material and design guidelines for all positioning templates). (Fig.4) — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 14: Controller Adjustment

    (Flanged) 120-130 #10 or 3/16" 130-140 Aluminum 1/4" High 140-150 5/16" High 150-160 NOTE: Be sure that proper observation of all safety precautions are in place before performing the next step. — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 15: Weld Quality

    B. To adjust the voltage upwards (increase weld heat), turn the voltage selector knob clockwise in small increments to a higher setting. When weld quality is consistently satisfactory, the CD 100 is properly installed and setup. — CD 100 Stud Welder...

  • Page 16: Preventive Maintenance

    (i.e., Hammer—banging studs to test welds or break ferrules, Scraper—removing rust, scale or weld splatter, etc.) TROUBLESHOOTING When troubleshooting the CD 100, the following precautions must be observed. 1. Controller power must be TURNED OFF! NOTE: Dangerous voltage levels can still be present in the controller—even after power is disconnected.

  • Page 17: Troubleshooting Chart

    “Z” of plug. No reading should be observed while gun trigger is in the released position. D. Faulty printed circuit board. Replace with new PC board if defective. — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.
  • Page 18 Replace with new PC board if defective. If you need assistance with setup, or operation, call MIDWEST FASTENERS Technical Support at (800) 852-8352 Monday through Friday between 8am and 5pm Eastern time. — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 19: Cd 100 Welder Specifications

    (* Dependent on stud size.) Weld Voltage ....34–175 VDC Capacitance - Low ... 84,000 mfd High ..168,000 mfd Cables ......15' Ground Cable (2 supplied /recommended) 25' Extension Set (recommended minimum) — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 20: Cd 100 Welder Exploded View & Parts List

    Internal Weld Cable 050-1005-01 Jumper Bar 060-3068-00 Camlok Connector Receptacle 060-3115-00 R&S Connector Receptacle 050-1001-16 SCR Heat Sink Bracket 050-1003-73 Main SCR 050-1001-62 Data Plate (Not shown) 050-1004-80 Resistor Mounting Bracket (Not shown) — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 21: Cd 2P Gun Specifications

    (not including cables) Pin/Stud Range ....14 ga. – 3/8" dia. Weldable Materials ..Mild Steel, Stainless, Brass & Aluminum Material ......High strength, impact resistant, polycarbonate Cable Length ....6' — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 22: Cd 2P Gun Exploded View & Parts List

    Boot Retainer 060-3222-06 060-3222-06 060-3222-06 060-3222-06 060-3222-06 060-3222-06 Boot Retainer Split Ring Boot Retainer Split Ring Boot Retainer Split Ring Boot Retainer Split Ring Boot Retainer Split Ring Boot Retainer Split Ring — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 23: Cd 100 Electrical Schematic

    CD 100 STUD WELDING SYSTEM ELECTRICAL SCHEMATIC — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 24: Notes

    NOTES — CD 100 Stud Welder ©2001 MIDWEST FASTENERS, INC.
  • Page 26 450 Richard Street • Miamisburg, OH 45342 Phone: (937) 866-0463 • Fax: (937) 866-4174 (800) 852-8352 3/2015...

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