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MIDWEST FASTENERS CD80 Owner's Manual

Capacitor discharge stud welding system
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CD80
Solid State
Capacitor Discharge
Stud Welding System
Ownerʼs Manual

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Summary of Contents for MIDWEST FASTENERS CD80

  • Page 1 CD80 Solid State Capacitor Discharge Stud Welding System Ownerʼs Manual...
  • Page 2 CD 80 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

    TABLE OF CONTENTS Warranty ..................4 GENERAL Safety Precautions ................5 What is Stud Welding ? ..............6 INTRODUCTION How Does CD Stud Welding Differ From ARC Stud Welding ? ..6 CD 80 Overview ................8 CD 80 Installation ................9 INSTALLATION CD 80 Setup .................

  • 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 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 7: What Is Stud Welding

    • Arc. ARC STUD WELDING ? The difference between these two methods involves the power source used to provide the welding current, the workpiece size, base material and the stud design. — CD 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.
  • 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 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 9: Cd 80 Overview

    HEARING PROTECTION WARNING Voltages inside the unit can reach 200 volts D.C. even if the unit is turned off. All repair work should be handled by factory trained personnel. HIGH VOLTAGE — CD 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 10: Cd 80 Installation

    5. Connect the Gun Cable male cam-lok connector to the Controller receptacle marked “GUN.” 6. Connect the Gun Cable control connector to the Controller receptacle marked “CONTROL.” 7. Plug the Controller Power Cord to appropriate power source. — CD 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 11: Cd 80 Setup

    • Insulation Pins with Collet Protector (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 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 12: Insulation Pins

    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 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 13: Weld Studs

    Weld Gun with “B” “B” Template Weld Piece Template Template Stop Collet Adaptor Stud Adaptor Faceplate Faceplate 1/8"- 3/16" Protrusion Template Adaptors are used when precise positioning of the stud is required. (Fig.4) — CD 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 14: Controller Adjustment

    4. Pick up the weld gun and place the stud firmly against the workpiece (The test workpiece should be a material that is similar to the workpiece to be welded to in actual production.) — CD 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 15: Weld Quality

    8am and 5pm voltage selector knob clockwise in small increments to a higher Eastern time. setting. When weld quality is consistently satisfactory, the CD 80 is properly installed and setup. — CD 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 16: Preventive Maintenance

    PREVENTIVE Your MIDWEST FASTENERS welder is designed for long service with minimal care. Ordinary common sense maintenance will keep it operating MAINTENANCE efficiently. The following are a few tips on preventive maintenance. 1. Treat the cables with respect. Avoid sharp bends or kinks which may break the cables.

  • 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 80 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 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 19: Cd 80 Welder Specifications

    Weld Mode....... Contact Weld Rate ......20 /minute (maximum)* (* Dependent on stud size.) Weld Voltage ....35–175 VDC Capacitance ...... 98,000 mfd Cables ......15' Ground Cable 25' Extension Set — CD 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 20: Cd 80 Welder Exploded View & Parts List

    SCR Heat Sink Bracket 050-1003-73 Main SCR 181-1300-02 1/4-20 x 3/4 Hex Head Bolt 181-1260-02 1/4 Split Lock Washer 181-1260-41 1/4 Flat Washer 181-1100-02 1/4-20 Hex Nut 050-1001-62 Data Plate (Not shown) — CD 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 21: Cd 2P Gun Specifications

    (not including cables) Pin/Stud Range ....14 ga. – 5/16" dia. Weldable Materials ..Mild Steel, Stainless, Brass & Aluminum Material ......High strength, impact resistant, polycarbonate Cable Length ....6' — CD 80 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 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 23: Cd 80 Electrical Schematic

    CD 80 STUD WELDING SYSTEM ELECTRICAL SCHEMATIC — CD 80 Stud Welder ©2001 MIDWEST FASTENERS, INC.

  • Page 24: Notes

    NOTES — CD 80 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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