Pro-Weld CD-312 User Manual

OPERATION/MAINTENANCE

MANUAL

PRO WELD

CD-312

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

TABLE OF CONTENTS

INTRODUCTION

WARRANTY

UNPACKING YOUR UNIT

SUGGESTED SAFETY PRECAUTIONS

GENERA

THE CD WELDING PROCESS

POWER REQUIREMENTS

SYSTEM SPECIFICATIONS

WELDING SYSTEM HOOK-UP

9.1

9.2

9.3

L DESCRIPTION

Straight Polarity Reverse Polarity Cuphead Pin

1

2

3

4

4 5 6

10.0

11.0

11.5

12.0

13.0

14.0

15.0

16.0

17.0

SYSTEM OPERATION

GUN SET-UP

11.1

11.2

11.3

11.4

11.6

WELDABLE MATERIAL COMBINATIONS 15

CAUSES OF

TROUBLE SHOOTING POOR WELDS 16

ROUTINE WELDER MAINTENANCE 17

ASSEMBLY –CD-312 CONTROLLER

16.1

TROUBLE SHOOTING – ELECTRICAL 22

9

Standard Installing or Changing Collets or Chucks 10 For Weld Pins with Collet Protector 10 Template Adapter Collet Protector with Blunt Leg 11 Parts List LD CD Handgun 14

PC Board Assembly Drawing

POOR OR ERRATIC WELDS 16

11

21

7

9

18,19,20

18.0

19.0

CHECK LIST CD-312 SYSTEM P.N. 100-0108 24

CHECK LIST CD-312 SYSTEM P.N. 100-0109 24

PRO WELD

CD-312

LIST OF FIGURES

1

2 STRAIGHT POLARITY HOOK-UP 4

3

4

5

6 STANDARD GUN SETUP 9

7

8 TEMPLATE ADAPTER GUN SETUP 11

9 COLLET PROTECTOR/

10

CD CONTACT PROCESS

REVERSE POLARITY HOOK-UP

CUPHEAD PIN HOOK-UP

FRONT PANEL LAYOUT

COLLET PROTECTOR SETUP

LIGHT DUTY CD GUN

2

6

7

10

BLUNT LEG SETUP

13

5

11

12

13

14

15 G

16

17

18

19

HOT WELD

COLD WELD

ARC BLOW

WELD WITHOUT FOOTPIECE

PARTS LIST

PC BOARD

16

17

OOD WELD

21

16

17

18

(continued)

19

20

PRO WELD

CD-312

PRO WELD

CD-312

PRO WELD

CD-312

PRO WELD

CD-312

PRO WELD

1

.0 INTRODUCTION

Your new stud welding equipment is carefully constructed of the finest components and materials available. Used you years of profitable, efficient service.

The system incorporates the latest in enginee ing advances, for completely reliable end welding of mild steel, stainless steel, aluminum and lead free copper and brass fasten

A careful study of this manual will enable you to understand how the welder operates to insure proper performance under al

properly, this equipment will give

2.0 WARRANTY

The electrical and mechanical components of the stud welder are thoroughly performance i spected prior to assembly in the welder. The asse bled welder is completely performance checked. The welder is delivered to you in functional electro mechanical condition.

All p

arts used in the assembly of the welder and its accessories are fully warranted for a period of 1 YEAR from the date of delivery welding capacitors are warranted for a period of 1 YEAR from the date of delivery. The printed circuit boards for a period of 3 years.

the right to repair or replace, at their option, defe tive parts which fail during the guarantee period. No ment purchaser within ten (10) days after the defect is first discovered. The manufacturer does not assume any liability for paying shipping cost or any labor or m terials furnished where such cost are not expressly authorized in writing.

acces abuse, improper installation, maladjustment, or use not in accordance with the operating instructions fu nished by the manufacturer. The warranty is valid only when studs are purchased from sources a proved by the manufacturer or are of identical spec fi

used in all proweld equipment are warranted

Under the warranty, the manufacturer reserves

tice of any claim for warranty repair or replac

must be furnished to the manufacturer by the

The manufacturer does not warrant any parts or

sories against failures resulting from misuse,

cations to the manufacturer’s

ers.

l operating conditions.

. In addition, the

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CD-312

3

.0 UNPACKING YOUR UNIT

possible to the point of installation before unpacking it. Do not operate the unit from an extension power

r-

cord if possible. Once the unit is unpacked it is reco mended that you inspect it for any physical damage.

inspected at the factory. Upon hooked up to the recommended incoming power b fore welding. We recommend that you check that you have received all the items listed on the shipping check list. (see SECTION 1

adequate ventilation. Do not restrict the air flow through the side l the control housing.

Upon receipt of your unit, place it as close as

Your unit has been completely assembled and

receipt, the unit must be

8 or 19)

Place the unit in a large enough area to provide

ouvers. Do not allow water to enter

4.0 SUGGESTED SAFETY PRECA TIONS

ity of the welder to observe certain safety rules to i sure his personal safety and to protect those working near him.

Reference is directed, without endorsement or recommendation, t and Cutting, and to AWG Publication A6,1-66, Re om ing.

r-

i-

while welding or weld in the rain. Avoid wear-

In any welding operation, it is the responsibi

o ANSI Z49.1, Safety in Welding

mended Safety Practices for Gas-Shield Arc Wel

1. Always treat electricity with respect. Under open circuit conditions, the welding machine output voltage may be dang

2. Don’t work on live circuits or conductors. Disconnect the main power line before check ing the machine or perform nance operations.

3. Be sure the welding machine cabinet is properly grounded to a good electrical ground.

4. Don’t stand in water or on a damp floor

ing wet sweaty cloths when welding.

U-

erous.

ing any mainte

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PRO WELD

5. Don’t operate with worn or poorly con nected cables. Don’t operate weld gun with loose cable connections. Inspect all cable quently for insulation failures, exposed wires,

loose connections, and repair as needed.

6. Don’t overload welding cab to operate with hot cables.

7. Don’t weld near flammable materials or liq uids, in or near atmospheres, or o ing explosive gases.

8. Don’t weld on containers which have held combustible or flammable materials, or on ma terials which give off flammable or toxic va pors when heated, without proper cleaning,

purging, or inerting.

les or continue

n ducts carry

-

s fre

CD-312

1

10 volt AC line voltage. The system comes complete

with power cord, weld cables and gun. Just add the

-

accessories required for t This manual should provide all the information r quired for you to be able to set up, weld, and maintain the CD-312 welding system.

6.0 THE CD WELDING PROCESS

common method of CD stud welding. Practically foolproof, it produces no reverse side marking in most cases and is suitable for most commercial and industrial applications.

accessories for the length and diameter stud you are going to weld. Refer to the CD Acc and CD Stud Welding Gun Section for information on accessories and gun set

Contact welding

First

, the gun must be set

he stud size to be welded.

e-

is the simplest and most

-up with the proper

essories Guide

-up.

9. Be sure t when welding in confined spaces.

10. Never look at the electric arc without wear ing protec

11. Always use the proper protective clothing, gloves, ect.

12. Never strike an arc when near a bystander who is unaware of the dangers of ultraviolet light on their eyes.

5.0 GENERAL DESCRIPTION

CD-

tained heavy duty capacitor discharge power supply capable of welding up to 5/16” flanged studs in mild steel or stainless steel It can weld up to 1/4 flanged studs (5/16” weld base diameter) in aluminum or brass.

for longer life and has been designed for easy mai te

nance and field service. This welder uses standard

312 HEAVY DUTY PORTABLE

CD ST

The CD-312 portable CD welder is a self co

The CD

o provide for proper ventilation

tive eye shields.

UD/PIN WELDER

(3/8” in weld base diameter).

-312

utilizes a solid state control board

n-

1 2

-

Initial Contact

3 4

Forced Into Molten Pool

(FIGURE 1 CONTACT CD WELD)

base material (SEE FIGURE 1). Verify that the gun is held perpendicular to the work di porizes the tip. The proper tip design is critical. This is what determines the length of time of the weld. An arc is briefly sustained which melts the stud base su face and the work surface directly underneath the stud. The spring pressure in the gun then forces the stud into the molten pool, completing the weld in a proximately six milliseconds.

The stud is first placed in contact with the

scharges the capacitors through the stud which v

During Weld

After Weld

. Pulling the trigger

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PRO WELD

T

his technique, when equipment is set up properly, is simple and easily mastered. The same power su ply is capable of welding many different sizes and materials of fasteners. If you require assistance in se

lecting the proper accessories, contact our cu tomer service department or your field represent tive.

7.0 POWER REQUIREMENTS

110 VOLT OPERATION

110 volt AC 60 H: Internal :

circuit breaker Integral 9 foot power cord

25 amp service 20 amp; (P/N: 104-0021)

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CD-312

Capacitance:

88,000 uF nominal

Weld Mode:

Polarity:

Power Required:

Int

STANDARD GUN & CABLE SPECIFICATIONS

Contact

Straight or Reverse

110 Volt AC 60 Hz 25 Amp

ernal Fusing:

20 Amp Circuit Breaker 3AG 1 Amp 250 volt (2 on PC board)

IF EXTENSION REQUIRED

Cable Length

50

12’ 25’ 30’

110 Volt #16/3 #16/3 #14/3 #12/3

8.0 SYSTEM SPECIFICATIONS

Weight:

48 Lbs.

Size:

Ch

Panel Controls:

Weldable Materials:

Brass, Zinc coated, Galvanized

Weldable Stud Diameter:

Weld Rate:

Weld Voltage:

45-

8 1/2” W x 10” D x 16 1/2” H

21.6 cm W x 25.4 cm D x 42 cm H

assis:

16 Ga. Steel (Painted International Orange)

Power Voltage Control

Steel, Stainles

12 Ga. Through 3/8” Weld Base (Max W.B. Dia.

24 per minute 5/16”

185 VDC

s steel, Aluminum, Copper,

For AL=5/16” {1/4” thread})

WELD GUN-LIGHT DUTY PRECISION CD CONTACT

Part Number:

300 300-

Weight:

2 lbs. (not including cable) (

Size:

Weldable Stud Diameter:

14 Ga. Thr

Material:

Integral Gun Cable Length:

Connectors:

Cables

Ground Cable:

lbs. (including 25 ft. #4 weld cable & 16

SOW control cable)

6 1/2” x 5 3/4” x 2”

High strength, impact resistant, glass fiber re inforced polycarbonate

25 feet – #4 AWG

Male Camlok / 2 Pin Hubbell Male

(1) #4 x 15’

0100 B Collet Gun 0101 Taper Tip Gun

ough 1/4” Flanged

(P/N: 125-0100)

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PRO WELD

9.0 WELDING SYSTEM HOOK-UP

9.1 A. Connect ground cable connector (1A) into c receptacle marked GROUND. Twist until it locks. Attach “C” clamp (2) to the w (CLEANED AREA).

B. Connect the gun control cable (3A) into the female receptacle (3).

C. Connect the gun weld cab locks.

D. Connect AC power cable to AC outlet.

The welding cables are coiled.

Straight Polarity (Standard Set-Up) (see Figure 2)

le (4A) into the receptacle marked GUN (4). Twist clockwise until it

gun welding and control cables must be laid out in a straight line. Poor weld quality may result if

CD-312

amlok (1). The camlok should be connected into the

orkpiece (5)

NOTE:

3

3A

1

1A

2

Figure 2 Straight Polarity Hook-Up

4

4A

5

PAGE 4

PRO WELD

9.2 Reverse Polarity (Recommended for brass or galvanized) (see Figure 3)

A. Connect ground cable connector (1A) into camlok ( receptacle marked GUN. Twist until it locks. Attach “C” clamp (2) to the workpiece ( AREA).

B. Connect the gun control cable (3A) into the female receptacle (3).

C. Connect the gun weld cable (4A) in it locks.

D. Connect AC power cable to AC outlet.

The gun wel welding cables are coiled.

ding and control cables must be laid out in a straight line. Poor weld quality may result if

to the receptacle marked GROUND (1). Twist clockwise until

CD-312

4). The camlok should be connected into the

5) (CLEANED

NOTE:

3

3A

4

4A

2

Figure 3 Reverse Polarity Hook-Up

1

1A

5

PAGE 5

PRO WELD

9.3 A. Connect ground cable connector (1A) into camlok (1). The camlok should receptacle marked CUPHEAD. Twist until it locks. Attach “C” clamp (2) to the workpiece (5) (CLEANED AREA)

B. Connect the gun control cable (3A) into the female receptacle (3).

C. Connect the gun weld cable (4A) into the receptacle locks.

D. Connect AC power cable to AC outlet.

The gun welding and control cab welding cables are coiled.

Cuphead and Power Point pin hook-up (see Figure 4)

.

les must be laid out in a straight line. Poor weld quality may result if

CD-312

be connected into the

marked GUN (4). Twist clockwise until it

NOTE:

3

3A

1

1A

5

2

Figure 4 Cuphead Pin Hook-Up

4

4A

PAGE 6

PRO WELD

1

0.0 SYSTEM OPERATION

(see Figure 4)

CD-312

1.

2. ready indicator light (3), a contact light (4) and a trig

3. to the lowest setting.

4. tion. The integral indicator light (1) will turn on.

5.

The CD-312 is designed for simple, yet precise operation.

It has an “ON-OFF” toggle

Before turning the unit “ON”, the voltage control knob (2) should be turned counter-clockw

With all cables connected, turn the unit on by putting the rocker switch (1) in the “ON” pos

When the capacitors reach the charge voltage setting, the ready light (

1

switch/indicator light (1) and a variable voltage control dial (2), a

ger light (5) on the front panel.

4) will turn on.

2

ise

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3

4

5

Figure 5 Front Panel Layout

PAGE 7

PRO WELD

S

etting the Weld Voltage/Capacitance

clockwise to increase the weld voltage until the indi number for the particular stud size that you are welding. (See the set up information

Once the voltage control knob is set to

a higher setting, turning it counterwill NOT reduce the volta bank, until the toggle switch (1) is turned “OFF” (for approximately 10 seconds).

ages corresponding to various stud sizes. The approximate voltages for each stud size is as follows:

45 – 65 – 95 95 – 120 – 145 – 180 –

Slowly turn the voltage control knob

cator knob is pointing at the appropriate

chart).

NOTE:

clockwise

ge on the capacitor

The settings are marked with the vol

60 VDC

120 VDC

145 VDC 180 VDC 185VDC

VDC

#8

#10

Min. 12 ga.

1/4” MAX.

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CD-312

The voltage charge on the capacitor bank is read on the digital panel meter. The ready light indicates when the capacitors are c welded.

Contact Light

ceptable electrical connection between the stud and ground. This light will turn on when the stud is placed in contact with the ground.

Trigger Light

The trigger light indicates there is a co plete circuit to the unit through the gun control c ble and switch. This light will turn on when the gun trigger is pressed.

The contact light indicates there is an a

harged and a stud may be

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11.0 GUN SET-UP

11.1 STANDARD (see Figure 5)

The standard gun set-up is used for welding the majority of applications. It co adjustable face plate, two legs, a foot, B-collet, stop, and spring for your specific stud size.

A step to set-up and operate the standard CD gun.

To prepare for stud welding, it is necessar have the proper accessories for the stud to be welded. Those required are the legs, footpiece, spring, collet, and appropri A 3/32” and a 5/32” hex wrench are the only tools needed for the adjustment of the gun.

-by-

step explanation of the correct way

nsists of the standard

y to

ate screws and washers.

CD-312

For CD welding, the stud normally should be engaged for all but 1/4” of its length, whenever po si

ble. Selecting the proper stop will accomplish this for you. The objective of the collet is to maintain a firm grip on the faste and a good electrical connection, yet allow for ease of loading.

made, assembly may begin. The footpiece is mounted on the legs using 10-32 x 3/4” socket head cap screws, inse the footpiece. These holes are recessed so that the head of the screws will not protrude.

the collet and stop into the open end of the gun shaft. Secure the collet in p shaft. Locate the legs, with footpiece attached, in the

Once the selection of the cor

After assembling the legs and footpiece, insert

ner to assure correct alignment

rect accessory is

rted through the holes at the base of

lace with two set screws on the

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Figure 6 Standard Gun Setup

h

oles provided in the gun faceplate. (It may be necessary to back off the socket screw in the faceplate to allow the legs to ente opening of the footpiece around the weld end of the fastener. Tighten the footpiece in position at this time. A justment for the plunge which is the distance the stud protrudes beyond the end of the footpiece can now be made. This is done b 32 x 1/4” set screws at the bottom of the faceplate using the 3/32” Allen wrench. Then sliding the legs f proper adjustment. Refer to the set chart for correct plunge distance (from 1/8” to 5/16”).

Correct set-up on all CD 1/8”- 5/16” plunge. This must be a sured for proper weld results in all cases.

r the hole). Center the

y loosening the two 10

or

-up

NOTE:

units is

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PRO WELD

The gun is now ready to weld. Select the proper setting for the size stud to be welded. Voltage is determined by the weld base d your power source is set for the proper polarity: straight for steel, reverse for galvanized.

11.2 INSTALLING OR CHUCKS

( The terms collet or chuck are different names for the same device). The collet holds the pin or be welded. It is secured to the gun shaft by two set screws. These screws are loosened to remove or r place a collet. Tighten these screws snugly to secure the collet in place.

weldin collet. If a collet becomes damaged or broken, it must be replaced. You may also need a stop.

When you change the size of the stud you are

g, you must also change to the appropriate

OR CHANGING COLLETS

iameter. Be sure

stud to

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CD-312

therefore, the same setup is applicable

There are two standard sizes And 10 ga. It is used with the round faceplate and three blunt legs. The collet protector slides over the coll screws. The insert, which takes the place of the I teral stop, is replaceable.

The stud is pushed into the chuck until the flange bo toms out on the insert. The collet protector is not available for studs larger than 10 ga.

1. It does not require a pin stop.

for a range of pin lengths.

2. There is a fixed adjustments necessary.

3. It provides stability at the weld end of the pin.

et and fastens to the chuck with three allen set

plunge, no gun

available: 12 ga.

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11.3 GUN SET-UP FOR WELD PINS WITH COLLET PROTECTOR (see Figure 6)

The collet protector has several advantages

over the standard set

-up.

combination can alternately be used with the collet protector as shown in Figure 7.

The standard adjustable legs and footpiece

PAGE 10

Figure 7 Collet Protector Gun Setup

PRO WELD

1

1.4 TEMPLATE ADAPTER (see Figure 7)

The template adapter is used when precise location or positioning of the CD stud is requir It is used with the round faceplate and does not r quire a footpiece or legs. The adapter is fastened to the faceplate and provides a fixed distance b tween the collet and work. The plunge is set by u ing the correct stop in the collet. A template can then be fabricated to enable very precise locating of a particular stud.

The template adapter is available in two

sizes, (1” and 1-1/4” diameter).

ed.

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CD-312

1

1.5 COLLET PROTECTOR/BLUNT LEG

nately be used with the collet protector as shown in Figure 8.

(see Figure 8)

The round faceplate, with blunt legs, can alte

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Figure 8 Template Adapter gun setup

Figure 9 Collet Protector/Blunt Leg Setup

PAGE 11

PRO WELD

CD-312

PAGE 12

Figure 10 Light Duty CD Gun

PRO WELD

11.6 PARTS LIST LIGHT DUTY CD HANDGUN

Part No. 300-0100

ITEM

PART NO.

DESCRIPTION

CD-312

QTY 1 033-384 2 001-800 3 033-610 4 033-799 5 033-016 6 033-382 7 049-955 8 9 033-404 10 033-381 11 036-496 12 033-662-25 13 033-658-25 GUN CONTROL CABLE (25 FT.) 1 14 033-881

NOT USED

GUN (CD) REAR CAP MOLDED 1 SPRING MAIN HEAVY SILVER GUN (CD/DA) BEARING ASSEMBLY GUN (CD) HEX HEAD CAP SCREW GUN (CD/DA/FA) TRIGGER SPRING M SC GUN (CD/DA/FA) CABLE CLAMP (ALUM. BLOCK) TRIGGER SWITCH GUN (CD/DA/FA) TRIGGER BUTTON MOLDED GUN (FL) SHAFT BLOCK – A GUN WELD

GUN BODY RH & LH STD.CD MACHINED

SHAFT TUBE

REW SET MS, BRASS PLT

CABLE (25 FT.)

1

3

1

2

1

1 15 033-445 16 033-447 17 033-665 18 033-446 19 033-608 20 018-375 21 016-876 22 033-757 23 009-929 24 016-378 25 028-833

GUN (CD/FL) SHAFT BOOT ASSY GUN (CD) SHAFT BOOT RETAINING RING GUN (CD) GUN (CD) SHAFT BOOT SNAP RING GUN (CD) WELD PIGTAIL ASSY SCREW PAN HEAD WASHED, LOCK INTO. TOOTH LEG (CD) STD.ADJ. 7” FLAT WASHER SOCKET HEAD CAP SCREW STD. FOOTPI

FACEPLATE – STD. ADJUSTABLE

2

ECE

1

2 REF. 2 REF. 2 REF. 1 REF.

PAGE 13

PRO WELD

CD-312

12.0 WELDABLE MATERIAL COMBINATIONS

Structural Steel (

Aluminum – Most alloys of the 1100, 3000 and 5000 series.

Zinc All

BASE MATERIAL

Mild Steel (1008-1018)

Galvanized Sheet (duct-”Q” Decking

Must Be Clean

oys (Die Cast)

)

STUD MATERIALS

Mild Steel 1008, 1018 Stainless Steel 304, 305 Brass 65 Copper, Silicon/Bronze

Mild Steel 1008 Stainless Steel 304,305

Mild Steel 1008,1018 Stainless Stee Brass 65

Aluminum 1100,5356

Aluminum 1100, 5356

-35, 70-30

-1018

l 304,305

Medium Carbon Steel (1030-1018)

Lead Free Brass Lead Free Rolled Brass Elec

trolytic Copper

Mild Steel 1008, 1018 Stainless Steel 304,305 Brass 65

Mild Steel 1008, 1018 Stainless Steel 304, 305 Copper, Silicon/Bronze

-35, 70-30

PAGE 14

PRO WELD

1

3.0 CAUSE OF POOR OR ERRATIC

WELDS

CD-312

12. Incorrect spring. (REPLACE WITH PROPER SPRING)

1. Loose collet. Does not grip stud tightly. (REPLACE) Not enough engagement of stud to co let. (CHANGE STOP)

2. Fault or loose ground connection. (REPAIR OR TIGHTEN)

3. Poor surface condition of base material, excess oil, grease, rust, ect. (CLEAN)

4. Voltage or capacitance setting too low or too high. (ADJUST TO DIAMETER OF STUD)

5. Broken or loose cables. (REPAIR)

6. Dirt in gun. (CLEAN)

7. Incorrect polarity. (CABLES HOOKED-UP WRONG)

8. Use of center punch USE CENTER PUNCH OR DEEP SCRIBES)

or deep scribe. (DO NOT

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ive

13. Poor stud quality.

14.0 TROUBLE SHOOTING POOR WELDS

Figure 11 Weld too Hot

Weld too Hot

A) Decrease voltage. B) Decrease capacitance. C) Increase stud protrusion. D) Increase spring pressure.

9. Cables too closely coiled.

10. Arc blow is evidenced by “one side severe cases there will be no melting under one edge of flange while the opposite side is gouged out or ap

pears excessively hot. The principle cause of arc blow is magnetic field induced by the current flow during the weld. It occurs most often on long, na row strips of metal or near edges of sheets or plates. In some cases, a change in grounding positions, or two grounds on the wor edge of work, will correct the problem. For assi tance in severe cases, contact your local sales repr sentative.

11. Incorrect plunge setting. (ADJUST TO PROPER SETTING)

” welds. In

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k piece, one at each end or

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Figure 12 Weld too Cold

Weld too Cold

A) Increase voltage. B) Increase capacitance. C) Decrease stud protrusion. D) Decrease spring pressure.

PAGE 15

PRO WELD

CD-312

1

5.0 ROUTINE WELDER

MAINTENANCE

with minimum care. Ordinary common sense maint nance will keep it operating efficiently.

Your CD-312 is designed for long service

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Figure 13 Arc Blow

Arc Blow

A) Use double grounds. B) Ground too close or not spaced

Figure 14 Weld without footpiece

Weld without footpiece

A) Use standard footpiece. B) Use template adapter. C) Use tripod blunt legs.

bles with respect. Avoid sharp bends and kinks which may break the cables. Don’t use the cables as a “tow line” to move the cont the cables where they enter the gun or at the conne tors.

the cover of the controller and clean with air and a soft brush around the

3. weld cable connections and make sure all the screws on the capacitor terminals are t pounds.

1. Treat the welding, ground, and control c

rol. Avoid damage or straining

2. It is good practice to occasionally remove

components.

CAUTION Be sure the controller is disconnected from the power before removing the pro tective cover.

While the cover is removed, tighten all the

orque to 30 inch

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Figure 15 Good Weld

PAGE 16

NOTE:

Keep the gun free of

dust, dirt or foreign

material

PRO WELD

CD-312

16.0 ASSEMBLY CD-312 CONTROLLER

1A

1

(see Figure 15,16, & 17)

2

ITEM 1 1A 2 SCR Mounting 124-0026 3 4 5 6 7

3

Figure 16 Parts List

DESCRIPTION Knob

102-0060

Charge Pot 25K

Main SCR Buss Bar Buss Bar Capacitor Chassis

124-0037 124-0036

106-0023

101-0016

5

4

111-0001

108-0001

6

PART NUMBER

7

PAGE 17

PRO WELD

14

15

16

CD-312

17

8

ITEM

9

10

8 9 10 11 12 13 14 15 16 17

11

Figure 17 Parts List

DESCRIPTION Terminal Strip Transformer

102-0020

105-0010 Dropping Resistor Discharge Resisto Nichrome Resistor PC Board Charging SCR Diode Charging Bridge

600-0007

108-0002

108-0027

108-0017

Safety Discharge SCR

12

13

PART NUMBER

112-0042

r 112-0041

112-0043

108-0042

PAGE 18

PRO WELD

18

19

CD-312

20

21

22

24

Figure 18 Parts List

ITEM 18 19 20 21 22 L 23 224

DESCRIPTION Power Switch LED Panel Meter LED Red LED Green

Female Camlok

104-0013

103-0002

108-0028

108-0029

ED Amber

Pole Female Hubbell

108-0030

107-0002

23

PART NUMBER

107-0031

PAGE 19

PRO WELD

CD-312

16.1 PC BOARD ASSEMBLY DRAWING FU2 and FU3 are 3AG 1 ampere fuses

OP1

R24

R34

D11

R30 R25 R17

R16 R18 R28

R27

D10

V5

V4

R20 R26 R19

D14

D13

R23 R40 R37

+

C9

R36

D21

D16

C6

FU2

OP4

R33

R13

V2

V1

R10

R43

R29

R7

OP2

D18

R15 D7 D6 R3

R1

R2

D8

ZD2

ZD1

D9

R8

R39

C7

D20 D19

FU3

V3

D2

R5

D1 R9

D3

R14

R4

D5

D23

+

C4

R41 R22

+

V7

V6

C5

OP3

D4

ZD3 R6

R32

R12 R11

C1 C2

R31

ZD4

ZD5

D22 D17

R35

R44

+

VR1

R42

+

C3

R38

PAGE 20

Figure 19 PC Board

PRO WELD

CD-312

17.0 TROUBLE SHOOTING – ELECTRICAL

When troubleshooting the power unit/controller (welder), the following precautions must be

1. Welder must be TURNED OFF!

2. Unplug power cable from welder and wait at least two minutes before checking compo

3. The use of a volt/ohmmeter is recommended where any voltage may be present.

4. Use a continuity tester ( or troubles

5. Possible causes marked with a star (*) are generally the most common problems.

P

ROBLEM

1. Welder does not turn on and

loose wire connection in the plug.

will not weld.

hooting light) for continuity checks only.

POSSIBLE CAUSE

A. Power connections at Welder or 110 VAC outlet not complete.

*B. Broken power cable or

C. Fuse blown.

CORRECTIVE ACTION

Check connections.

Check wires for continu Repair break.

Replace fuse.

observed:

nents.

ity.

2. Fuse bl unit is turned on.

ows each time

Rupture hole. Replace

*A. Shorted weld capacitor.

B. Shorted rectifier (BR1)

C. Incorrect primary hookup.

D. Shorted transformer assembly.

Check safety vent seal for

defective capacitor.

Check for a short across the rectifier with ohmmet Replace rectifier module if shorted.

Check transformer connect

Replace transformer.

er.

ions.

PAGE 21

PRO WELD

CD-312

PROBLEM

3. Welder turns on but does not operate

*B. Broken gun control cable or loose wire c

in either direction). Replace

4. Weld is excessively hot

regardless of vo setting.

A. Ground cable connections

ltage

In either direction). Replace

POSSIBLE CAUSE

not complete.

in the plug. Shorted or open trigger swit

*C. Faulty printed circuit board.

D. Sh

A. Shorted charge SCR.

orted weld SCR.

onnection

ch.

CORRECTIVE ACTION

Check for continuity

Check continuity between

pins on control plug while

trigger is depressed. Should read continuity.

Replace with new PC Board.

Check with ohmmeter (should not show continuity

rectifier module if shorted.

Check with ohmmeter ( should not show continuity

if shorted.

5. Poor and erratic

welding.

*B.

Faulty printed circuit

board.

C. Open voltage potentiometer.

A. Improper gun setup.

B. Improper grounding or cable setup or incorrec polarity.

C. Weld cables are coiled.

D. Incorrect voltag

E. Studs or pins not perpendicular to work surface.

e setting.

t

Replace defective legs.

Replace with new PC Board.

Replace defective voltage Potentiometer.

Check applicable gun setup Instruction page.

Check applicable cable setup Instruction page.

Straighten out cables.

Adjust as necessary.

Adjust legs as necessary.

PAGE 22

PRO WELD

18.0 CHECK LIST CD-312 SYSTEM PT. NO. 100-0108

STANDARD CD-312 WELDING SYSTEM COMPLETE WITH B-COLLET GUN AND 25’ #4 GROUND CA

ITEM

1. CD-

2.

3. GROUND CABLE #4 X 15’ 125-0100 1

4.

5.

19.0 CHECK LIST CD-312 SYSTEM PT. NO. 100-0109

DESCRIPTION

312 CONTROLLER 110 VAC GUN ASSY. B-COLLET w/INTEGRAL 2 & CONTROL CABLE 2-LEGS, and FOOTPIECE

MANUAL, HEX WRENCH SET

Operation and Maintenance CD

BLE

200-0012 1

5 FT.WELD

-312 1

1

PART #

300-0100 1

CD-312

QTY

STANDARD CD-312 WELDING SYSTEM COMPLETE WITH TAPER TIP GUN AND 25’ #4 GROUND CABLE

ITEM

1. CD-

2.

3. GROUND CABLE #4 X 15’ 125-0100 1

4. MANUAL, Operation and Maintenance CD-312 1

5.

DESCRIPTION

312 CONTROLLER 110 VAC GUN ASSY. TAPER TIP w/INTEGRAL 25 FT.WELD & CONTROL CABLE 2-LEGS, and FOOT

HEX WRENCH SET

1

PART #

200-0012 1

PIECE

300-0101 1

QTY

PAGE 23

MANUFACTURED BY

WELD

PRO

MADE IN THE U.S.A.