Pro-Weld CD-512 Operation Manual
OPERATION/MAINTENANCE
MANUAL
PRO WELD
CD-512
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
TABLE OF CONTENTS
INTRODUCTION
WARRANTY 1
UNPACKING YOUR UNIT
SUGGESTED SAFETY PRECAUTIONS
GENERA
THE CD WELDING PROCESS
POWER REQUIREMENTS
SYSTEM SPECIFICATIONS
WELDING SYSTEM HOOK-UP
9.1
9.2
SYSTEM OPERATION
L DESCRIPTION
Straight Polarity
Reverse Polarity
1
1
1
2
2
3
3
4
4
5
6
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
GUN SET-UP 8
11.1
11.2
11.3
11.4
11.5
11.6
WELDABLE MATERIAL COMBINATIONS 13
CAUSES OF POOR OR ERRATIC WELDS 14
TROUBLE SHOOTING POOR WELDS 14
ROUTINE WELDER MAINTENANCE 15
ASSEMBLY –CD-512 CONTROLLER
16.1 PC Board Assembly Drawing 19
TROUBLE SHOOTING – ELECTRICAL 20
CHECK LIST CD-512 SYSTEM P.N. 100-0110 22
Standard
Installin
For Weld Pins with Collet Protector
Template Adapter
Collet Protector w
Parts List HD CD Handgun 12
g or Changing Collets or Chucks
ith Blunt Leg 10
10
8
9
9
16,17,18
19.0
CHECK LI
ST CD-512 SYSTEM P.N. 100-0111 22
PRO WELD
CD-512
LIST OF FIGURES
1
2 STRAIGHT POLARITY HOOK-UP 4
3
5
6 STANDARD GUN SETUP 8
7
8 TEMPLATE ADAPTER GUN SETUP 10
9
10
11
CD CONTACT PROCESS
REVERSE POLARITY HOOK-UP
FRONT PANEL LAYOUT
COLLET PROTECTOR SETUP
COLLET PROTECTOR/BLUNT LEG SETUP
HEA
VY DUTY CD GUN
HOT WELD
14
2
5
6
9
11
10
12
13
14
15
16
17
18
19
COLD WELD
ARC BLOW
WELD WITHOUT FOOTPIECE
GOOD WELD
PARTS LIST
PARTS LIST
PARTS LIST
PC BOARD
14
15
15
16
(continued)
(continued)
19
17
18
15
PRO WELD
CD-512
PRO WELD
CD-512
PRO WELD
CD-512
PRO WELD
CD-512
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 must be furnished to the manufacturer by the
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
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-512
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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PAGE 1
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-512
1
10 volt AC line voltage. The system comes complete
with power cord, weld cables and gun. Just add the
-
-
-
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-
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-512 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
512 HEAVY DUTY PORTABLE
CD ST
The CD-512 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).
-512
utilizes a solid state control board
n-
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1 2
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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
a-
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PAGE 2
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