MIDWEST FASTENERS CD 100 Owner's Manual
Ownerʼs Manual
CD 100
Solid State
Capacitor Discharge
Stud Welding System
CD100
Solid State
Capacitor Discharge
Stud Welding System
Owner’s Manual
• Installation
• Operation
• Maintenance
CD50 Stud Welder 0
0 C
MIDWEST FASTENERS, INC.
TABLE OF CONTENTS
GENERAL
INTRODUCTION
INSTALLATION
SETUP& OPERATION
Warranty ......................................................................................... 4
Safety Precautions .......................................................................... 5
What is Stud Welding? ................................................................... 6
How Does CD Stud Welding Differ From ARC Stud Welding? .... 6
CD 100 Overview .......................................................................... 8
CD 100 Installation ........................................................................ 9
CD 100 Setup ............................................................................... 10
Gun Set Ups
Insulation Pins........................................................................ 11
Insulation Pins with Internal Stop.......................................... 11
Weld Studs ............................................................................. 12
Weld Studs with Template Adaptor........................................ 12
Controller Adjustment .................................................................. 13
Making A T est W eld...................................................................... 13
MAINTENANCE
TROUBLESHOOTING
SPECIFICATIONS
Weld Quality ................................................................................. 14
Preventive Maintenance................................................................ 15
Troubleshooting............................................................................ 15
CD 100 Welder Specifications ..................................................... 18
CD 100 Welder Exploded View & Parts List ............................... 19
CD 2P Gun Specifications............................................................ 20
CD 2P Gun Exploded View & Parts List...................................... 21
CD 100 Electrical Schematic........................................................ 22
Notes............................................................................................. 23
MIDWEST FASTENERS, INC.
/or studs approved
SAFETY
PRECAUTIONS
EYE
PROTECTION
• Comply with all electrical, fire and other applicable codes or ordinances
in the installation and use of stud welding systems.
• Remove all combustible or volatile materials from the weld area.
Although weld splatter resulting from stud welding is normally minimal,
proper precautions should be taken when welding near or through
combustible materials to insure that sparks or weld material do not come
in contact with combustible material.
• Recommend wearing of eye protection at all times when welding.
Spectacle type frames with Shade No. 3 absorptive and filter lens and
side shields are suggested. Never look directly at the weld arc without
wearing ey e shields.
• Recommend use of proper ear protection with all CAPACITOR
DISCHARGE stud welding systems. The stud welding operator and
anyone working within five (5) feet of the stud welding operation should
use ear protection devices.
• Use of protective clothing is suggested. Type of clothing will vary as to
application, weld position and stud welding being used; however, in all
cases, it should be fire resistant and sufficient to protect welding
operator from weld splatter and material.
HEARING
PROTECTION
HIGH VOLTAGE
• Keep hands, clothing, etc. away from the weld stud, chuck and all other
parts in contact with them during the weld cycle.
• Keep weld cable and connectors in good condition. Inspect periodically
for broken insulation and/or other electrical hazards.
• Do not operate with worn or poorly connected cables. Inspect all cables
often for bare or exposed wires, broken insulation layers and/or loose
connections. Repair all such connections before welding use.
• Do not stand in water or on damp surfaces while welding. Avoid wearing
wet or sweaty clothes. Do not weld in the rain.
WARNING
Use extreme caution when servicing or troubleshooting
any component of this stud welding system.
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.
©2001
MIDWEST FASTENERS, INC.
—
CD 100 Stud Welder 5
WHAT IS STUD
WELDING?
Stud welding is a welding process where a “stud” (or similar metal part) is
instantaneously end-joined to a metal workpiece. This process involves the
same basic principles and metallurgical aspects as any other welding
process.
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
N
O
W
O
P
LOW
F
F
O
CD 100
C
D
+
C
+
GROUND CABLE
R
E
W
O
P
D
L
E
R
E
W
W
HIGH
C
D
CDSW-100-00
MIN MAX
E
G
A
T
L
O
L
V
O
R
E
T
G
N
A
O
T
L
C
O
V
D
L
E
N
U
–
L G
O
R
T
N
O
Extension
Cable Set
CDES-201-25
Weld Gun
CDPG-200-06
Ground Cable (2 ea.)
CDGC-201-15
The stud welding process is as follows. The stud is placed
in the collet of the
“Weld Gun” and then positioned against the workpiece. The weld gun trigger
is depressed and t
hrough operation of the stud welding controller and the
design of the stud, an arc is drawn which melts the base of the stud and a
proportionate area of the workpiece. The stud is then forced by the weld gun
into the molten pool and held in place until the metals resolidify. This high
quality fusion weld is completed in milliseconds.
HOW DOES
CD STUD WELDING
DIFFER FROM
ARC STUD WELDING?
6 ©2001
There are two different stud welding processes:
• Capacitor Discharge (called “CD” for brevity) and
• Arc.
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.
MIDWEST FASTENERS, INC.
—
CD100 Stud Welder
CD STUD WELDING
The CD stud welding process produces weld power through a rapid
discharge of the stored energy from a bank of capacitors. This stored
energy is usually derived from a standard 115 volt AC source. CD stud
welding, as a general rule, is used for studs 5/16" and less in diameter,
(or where thin base metals or dissimilar metals are to be joined.)
“CD” STUD WELDING PROCESS
ARC STUD WELDING
1. Stud is placed against workpiece
and weld gun trigger depressed
3. Weld gun forces stud
into molten metal
2. Stored energy is discharged
through special tip
4. Weld solidifies in
miliseconds
The ARC stud welding process produces weld power through one of three
standard DC welding power sources. These are Transformer-Rectifier type,
Motor/Generator type, or Storage Battery type. A ceramic ferrule is
required in ARC stud welding to maintain the proper atmosphere in the
weld area. ARC stud welding is generally used for studs over 1/4" in
diameter or where heavier base metals are involved.
©2001
MIDWEST FASTENERS, INC.
“ARC” STUD WELDING PROCESS
1. Stud is placed against workpiece
and weld gun trigger depressed
3. Weld gun forces stud
into molten metal
—
CD 100 Stud Welder 7
2. Stud is lifted by weld gun
and initiating arc is drawn
4. Weld solidifies and
ferrule is removed
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