ProWeld CD212 Operator - Red-D
Contents
1. WIELD CID 2 12 INTERNATIONAL 9 0 WELDING SYSTEM HOOK UP 9 1 Straight Polarity Standard Set Up see Figure 2 A Connect ground cable connector 1A into camlok 1 The camlok should be connected into the receptacle marked GROUND 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 marked GUN 4 Twist clockwise until it locks D Connect AC power cable to AC outlet NOTE The gun welding and control cables must be laid out in a straight line Poor weld quality may result if welding cables are coiled Figure 2 Straight Polarity Hook Up Page 4 PIRO 4 WELD CD 212 INTERNATIONAL 9 2 Reverse Polarity Recommended for brass or galvanized see Figure 3 A Connect ground cable connector 1A into camlok 4 The camlok should be connected into the receptacle marked GUN Twist until it locks Attach 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 marked GROUND 1 Twist clockwise until 1t locks D Connect AC power cable to AC outlet NOTE The gun welding and control cables must be laid out in a straight line Poor weld quality may result 1f welding cables are coiled Figure 3 Reverse Polarity Hook Up P2. CID Z12 When troubleshooting the power unit controller welder the following precautions must be observed 1 Welder must be TURNED OFF 2 Unplug power cable from welder and wait at least two minutes before checking components 3 The use of a volt ohmmeter is recommended where any voltage may be present 4 Use a continuity tester or troubleshooting light for continuity checks only 5 Possible causes marked with a star are generally the most common problems PROBLEM POSSIBLE CAUSE 1 Welder does not turn on A Power connections at and will not weld Welder or 110 VAC outlet not complete B Broken power cable or loose wire connection in the plug C Fuse blown 2 Fuse blows each time A Shorted weld capacitor unit is turned on B Shorted rectifier BR1 C Incorrect primary hookup D Shorted transformer assembly Page 18 CORRECTIVE ACTION Check connections Check wires for continuity Repair break Replace fuse Check safety vent seal for Rupture hole Replace defective capacitor Check for a short across the rectifier with ohmmeter Replace rectifier module if shorted Check transformer connections Replace transformer PROA PROBLEM 3 Welder turns on but does not operate 4 Weld is excessively hot regardless of voltage setting 5 Poor and erratic welding WELD INTERNATIONAL POSSIBLE CAUSE A Ground cable connections not complete B Broke
3. PROA WIEILID INTERNATIONAL OPERATION MAINTENANCE MANUAL 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 18 0 19 0 WIEILID INTERNATIONAL TABLE OF CONTENTS INTRODUCTION WARRANTY UNPACKING YOUR UNIT SUGGESTED SAFETY PRECAUTIONS GENERAL DESCRIPTION THE CD WELDING PROCESS POWER REQUIREMENTS SYSTEM SPECIFICATIONS WELDING SYSTEM HOOK UP 9 1 Straight Polarity 9 2 Reverse Polarity SYSTEM OPERATION GUN SET UP 11 1 Standard 11 2 Installing or Changing Collets or Chucks 11 3 For Weld Pins with Collet Protector 11 4 Template Adapter 11 5 Collet Protector with Blunt Leg 11 6 Parts List LD CD Handgun WELDABLE MATERIAL COMBINATIONS CAUSES OF POOR OR ERRATIC WELDS TROUBLE SHOOTING POOR WELDS ROUTINE WELDER MAINTENANCE ASSEMBLY CD 212 CONTROLLER 16 1 PC Board Assembly Drawing TROUBLE SHOOTING ELECTRICAL CHECK LIST CD 212 SYSTEM P N 100 0112 CHECK LIST CD 212 SYSTEM P N 100 0113 13 13 14 15 16 17 18 20 20 CID Z12 10 11 12 13 14 15 16 17 INTERNATIONAL LIST OF FIGURES CD CONTACT PROCESS STRAIGHT POLARITY HOOK UP REVERSE POLARITY HOOK UP FRONT PANEL LAYOUT STANDARD GUN SETUP COLLET PROTECTOR SETUP TEMPLATE ADAPTER GUN SETUP COLLET PROTECTOR BLUNT LEG SETUP LIGHT DUTY CD GUN HOT WELD COLD WELD ARC BLOW WELD WITHOUT FOOTPIECE GOOD WELD PARTS LIST PARTS LIST continued PC BOARD 1
4. 0 13 13 14 14 14 15 16 17 CID Z12 INTERNATIONAL CID Z12 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING SS f ean IA LL ie Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols A Marks a special safety message Means Note not safety related 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and tollow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found In the Safety Standards listed in Section NO TAG Read and follow all Safety Standards A Only qualified persons should Install operate maintain and repair this unit A During operation keep everybody especially children away ELECTRIC SHOCK can kil Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch l
5. 00 0100 GROUND CABLE 4 X 15 125 0100 MANUAL Operation and Maintenance CD 212 HEX WRENCH SET 19 0 CHECK LIST CD 212 SYSTEM PT NO 100 0113 QTY m STANDARD CD 212 WELDING SYSTEM COMPLETE WITH TAPER TIP GUN AND 25 4 GROUND CABLE ITEM 1 2 3 4 5 Page 20 DESCRIPTION PART CD 212 CONTROLLER 110 VAC 200 0015 GUN ASSY TAPER TIP w INTEGRAL 25 FT WELD amp CONTROL CABLE 2 LEGS and FOOTPIECE 300 0101 GROUND CABLE 4 X 15 125 0100 MANUAL Operation and Maintenance CD 212 HEX WRENCH SET QTY p so g ur SO 2 O MADE IN THE U S A
6. 3 INTERNATIONAL DESCRIPTION GUN CD REAR CAP MOLDED SPRING MAIN HEAVY SILVER GUN CD DA BEARING ASSEMBLY GUN CD SHAFT TUBE HEX HEAD CAP SCREW GUN CD DA FA TRIGGER SPRING M SCREW SET MS BRASS PLT GUN CD DA FA CABLE CLAMP ALUM BLOCK TRIGGER SWITCH GUN CD DA FA TRIGGER BUTTON MOLDED GUN FL SHAFT BLOCK GUN WELD CABLE 25 FT GUN CONTROL CABLE 25 FT GUN BODY RH amp LH STD CD MACHINED GUN CD FL SHAFT BOOT ASSY GUN CD SHAFT BOOT RETAINING RING GUN CD FACEPLATE STD ADJUSTABLE 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 FOOTPIECE CID Z12 QTY 2 REF 2 REF 2 REF REF Page 11 PRO RS INTERNATIONAL CD 2 2 12 0 WELDABLE MATERIAL COMBINATIONS BASE MATERIAL Mild Steel 1008 1018 Galvanized Sheet duct Q Decking Structural Steel Must Be Clean Aluminum Most alloys of the 1100 3000 and 5000 series Zinc Alloys Die Cast Medium Carbon Steel 1030 1018 Lead Free Brass Lead Free Rolled Brass Electrolytic Copper Page 12 STUD MATERIALS Mild Steel 1008 1018 Stainless Steel 304 305 Brass 65 35 70 30 Copper Silicon Bronze Mild Steel 1008 1018 Stainless Steel 304 305 Mild Steel 1008 1018 Stainless Steel 304 305 Brass 65 35 70 30 Aluminum 1100 5356 Aluminum 1100 5356 Mild Steel 1008 1018 Stai
7. PRING 13 Poor stud quality 14 0 TROUBLE SHOOTING POOR WELDS Figure 10 Weld too Hot Weld too Hot A Decrease voltage B Decrease capacitance C Increase stud protrusion D Increase spring pressure Figure 11 Weld too Cold Weld too Cold A Increase voltage B Increase capacitance C Decrease stud protrusion D Decrease spring pressure Page 13 WIELID INTERNATIONAL Figure 12 Arc Blow Arc Blow A Use double grounds B Ground too close or not spaced Figure 13 Weld without footpiece Weld without footpiece A Use standard footpiece B Use template adapter C Use tripod blunt legs Figure 14 Good Weld Page 14 CID Z12 15 0 ROUTINE WELDER MAINTENANCE Your CD 212 is designed for long service with minimum care Ordinary common sense mainte nance will keep it operating efficiently 1 Treat the welding ground and control ca 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 control Avoid damage or straining the cables where they enter the gun or at the connec tors 2 It is good practice to occasionally remove the cover of the controller and clean with air and a soft brush around the components CAUTION Be sure the controller is disconnected from the power before removing the pro tective cover 3 While the cover is removed tighten all the weld cable connections and
8. T OPERATION 110 volt AC 60 H 20 amps Circuit protection 15 amp circuit breaker P N 104 0020 Integral 9 foot power cord IF EXTENSION REQUIRED Cable Length 110 Volt 12 16 3 23 1116 3 30 14 3 50 12 3 8 0 SYSTEM SPECIFICATIONS Weight 26 Lbs Size 9 W x 11 3 4 D x8 1 2 22 9 W x 29 8 cm Dx 21 6 cm H Chassis 14 Ga Aluminum Painted International Orange Panel Controls Power Voltage Controls Weldable Materials Steel Stainless steel Aluminum Copper Brass Zinc coated Galvanized Weldable Stud Diameter 14 Ga Through 1 4 Flanged Max W B Dia For AL 5 16 1 4 thread Weld Rate 12 per minute Weld Voltage 45 200 VDC CID Z12 Weld Mode Contact Polarity Straight or Reverse Power Required 110 Volt AC 60 Hz 20 Amp Circuit Protection 15 Amp circuit breaker 3AG 1 Amp 250 volt fuses 2 on PC Board STANDARD GUN amp CABLE SPECIFICATIONS WELD GUN LIGHT DUTY PRECISION CD CONTACT Part Number 300 0100 B Collet Gun 300 0101 Taper Tip Gun Weight 2 Ibs not including cable lbs including 25 ft 4 weld cable amp 16 4 SOW control cable Size GUADA x 2 Weldable Stud Diameter 14 Ga Through 1 4 Flanged Material High strength impact resistant glass fiber re inforced polycarbonate Integral Gun Cable Length 25 feet 4 AWG Connectors Male Camlok 2 Pin Hubbell Male Cables Ground Cable 1 4x15 P N 125 0100 Page 3
9. age 5 d WUTRILID 10 2 2 INTERNATIONAL 10 0 SYSTEM OPERATION see Figure 4 1 The CD 212 is designed for simple yet precise operation 25 It has an ON OFF rocker switch indicator light 1 and a variable voltage control dial 2 on the front panel 3 Before turning the unit ON the voltage control knob 2 should be turned counter clockwise to the lowest setting 4 With all cables connected turn the unit on by putting the rocker switch 1 in the ON posi tion The integral indicator light 1 will turn on Setting the Weld Voltage Capacitance Slowly turn the voltage control knob clockwise to increase the weld voltage until the indicator knob is pointing at the appropriate number for the particular stud size that you are welding See the set up information chart Below NOTE Once the voltage control knob is set to a higher setting turning it counter clockwise will NOT reduce the voltage on the capacitor bank until the toggle switch 1 is turned OFF for approximately 10 seconds The settings are marked with the volt ages corresponding to various stud sizes The approximate voltages for each stud size is as follows 45 VDC Min 45 80 VDC 12 ga 6 Figure 4 Front Panel Layout 80 120 VDC 8 120 160 VDC 10 160 190 VDC 1 4 200VDC MAX Page 6 INTERNATIONAL 11 0 GUN SET UP For CD welding the stud normally should be engaged for all but 1 4
10. d you are welding you must also change to the appropriate collet If a collet becomes damaged or broken it must be replaced You may also need a stop 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 COLLET PROTECTOR rr O CD 2 2 1 It does not require a pin stop therefore the same setup is applicable for a range of pin lengths 2 There is a fixed plunge no gun adjustments necessary 3 It provides stability at the weld end of the pin There are two standard sizes available 12 ga And 10 ga It is used with the round faceplate and three blunt legs The collet protector slides over the collet and fastens to the chuck with three allen set screws The insert which takes the place of the In teral stop is replaceable The stud is pushed into the chuck until the flange bot toms out on the insert The collet protector is not available for studs larger than 10 ga The standard adjustable legs and footpiece combination can alternately be used with the collet protector as shown in Figure 10 IMPORTANT 1 8 TO 5 16 PROTRUSION A a imm PROTECTOR INSERT STD ADJUSTABLE FACE PLATE P N 033 685 7 STD ADJ LEG PIN 033 757 Figure 6 Collet Protector Gun Setup Page 8 INTERNATIONAL 11 4 TEMPLATE ADAPTER see Figure 7 The template adapter is used when precise location
11. eived all the items listed on the shipping check list see SECTION 18 or 19 Place the unit in a large enough area to provide adequate ventilation Do not restrict the air flow through the side louvers Do not allow water to enter the control housing 4 0 SUGGESTED SAFETY PRECAU TIONS In any welding operation it is the responsibil ity of the welder to observe certain safety rules to in sure his personal safety and to protect those working near him Reference is directed without endorsement or recommendation to ANSI Z49 1 Safety in Welding and Cutting and to AWG Publication A6 1 66 Rec ommended Safety Practices for Gas Shield Arc Weld ing 1 Always treat electricity with respect Under open circuit conditions the welding machine output voltage may be dangerous 2 Don t work on live circuits or conductors Disconnect the main power line before check ing the machine or performing any mainte 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 while welding or weld in the rain Avoid wear ing wet sweaty cloths when welding Page 1 WIELID INTERNATIONAL 5 Don t operate with worn or poorly con nected cables Don t operate weld gun with loose cable connections Inspect all cables fre quently for insulation failures exposed wires loose connections and repair as needed 6 Don t overload weldi
12. elding capacitors are warranted for a pe riod of one hundred twenty 120 days from the date of delivery Under the warranty the manufacturer reserves the right to repair or replace at their option defec tive parts which fail during the guarantee period Notice of any claim for warranty repair or replace 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 ma terials furnished where such cost are not expressly authorized in writing The manufacturer does not warrant any parts or accessories against failures resulting from misuse abuse improper installation maladjustment or use not in accordance with the operating instructions fur nished by the manufacturer The warranty is valid only when studs are purchased from sources ap proved by the manufacturer or are of identical speci CID Z12 3 0 UNPACKING YOUR UNIT Upon receipt of your unit place it as close as possible to the point of installation before unpacking it Do not operate the unit from an extension power cord if possible Once the unit is unpacked it is recom mended that you inspect it for any physical damage Your unit has been completely assembled and inspected at the factory Upon receipt the unit must be hooked up to the recommended incoming power be fore welding We recommend that you check that you have rec
13. ive electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Donotuse AC outputin damp areas if movementis confined or if there is a danger of falling e Use AC output ONLY if required for the welding process e f AC output is required use remote output control if present on unit Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conductor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Donotuse worn damaged undersized or poorly spliced cables Do not drape cables over your body This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards C
14. lose together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possible About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended WIELID INTERNATIONAL 1 0 INTRODUCTION Your new stud welding equipment is carefully constructed of the finest components and materials available Used properly this equipment will give you years of profitable efficient service The system incorporates the latest in engineer ing advances for completely reliable end welding of mild steel stainless steel aluminum and lead free copper and brass fasteners A careful study of this manual will enable you to understand how the welder operates to insure proper performance under all operating conditions 2 0 WARRANTY The electrical and mechanical components of the stud welder are thoroughly performance in spected prior to assembly in the welder The assem bled welder is completely performance checked The welder is delivered to you in functional electro mechanical condition All parts used in the assembly of the welder and its accessories are fully warranted for a period of ninety 90 days from the date of delivery In addi tion the w
15. make sure all the screws on the capacitor terminals are torque to 30 inch pounds NOTE Keep the gun free of dust dirt or foreign material PRO WELD INTERNATIONAL CID Z12 16 0 ASSEMBLY CD 212 CONTROLLER see Figure 15 16 amp 17 ITEM 1 0000 9 Figure 15 Parts List DESCRIPTION Chassis SCR Mounting Main SCR Capacitor 3 Transformer PC Board Discharge Resistor Safety Discharge SCR Charging SCR Buss Bar Diode Charging Bridge Buss Bar 150K 2 Watt PART NUMBER 101 0025 124 0026 108 0001 106 0023 105 0017 600 0013 112 0041 108 0042 108 0002 124 0034 108 0027 108 0017 124 0035 111 0002 Page 15 CID Z12 INTERNATIONAL STUD WELDER MADE IN USA GUN Figure 16 Parts List ITEM DESCRIPTION PART NUMBER 14 Knob 102 0060 15 Female Camlok 2 107 0002 16 2 Pole Female Hubbell 107 0031 17 Power Switch 104 0013 18 Circuit Breaker 104 0020 Page 16 d WUTEILID 0 2 2 INTERNATIONAL 16 1 PC BOARD ASSEMBLY DRAWING FUI and FU2 1 ampere fuses Figure 17 PC Board Page 17 WIELID INTERNATIONAL 17 0 TROUBLE SHOOTING ELECTRICAL
16. n gun control cable or loose wire connection in the plug Shorted or open trigger switch Faulty printed circuit board D Shorted weld SCR A Shorted charge SCR Faulty printed circuit board C Open voltage potentiometer A Improper gun setup B Improper grounding or cable setup or incorrect polarity C Weld cables are coiled D Incorrect voltage setting E Studs or pins not perpendicular to work surface CID Z12 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 in either direction Replace rectifier module if shorted Check with ohmmeter should not show continuity In either direction Replace if shorted 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 Replace defective legs Page 19 INTERNATIONAL 18 0 CHECK LIST CD 212 SYSTEM PT NO 100 0112 CID Z12 STANDARD CD 212 WELDING SYSTEM COMPLETE WITH B COLLET GUN AND 25 4 GROUND CABLE ITEM 1 2 3 4 5 DESCRIPTION PART CD 212 CONTROLLER 110 VAC 200 0015 GUN ASSY B COLLET w INTEGRAL 25 FT WELD amp CONTROL CABLE 2 LEGS and FOOTPIECE 3
17. ng cables or continue to operate with hot cables 7 Don t weld near flammable materials or liq uids in or near atmospheres or on ducts carry 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 9 Be sure to provide for proper ventilation when welding in confined spaces 10 Never look at the electric arc without wear ing protective eye shields 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 212 HEAVY DUTY PORTABLE CD STUD PIN WELDER The CD 212 portable CD welder is a self con tained heavy duty capacitor discharge power supply capable of welding up to 1 4 flanged studs in mild steel The CD 212 utilizes a solid state control board for longer life and has been designed for easy main tenance and field service This welder uses standard 110 volt AC line voltage Page 2 CID 2Z12 The system comes complete with power cord weld cables and gun Just add the accessories required for the stud size to be welded This manual should pro vide all the information required for you to be able to set up weld and maintain the CD 212 welding sys tem 6 0 THE CD WELDING PROCESS Contact welding i
18. nless Steel 304 305 Brass 65 35 70 30 Mild Steel 1008 1018 Stainless Steel 304 305 Copper Silicon Bronze WIELID INTERNATIONAL 13 0 CAUSE OF POOR OR ERRATIC WELDS 1 Loose collet Does not grip stud tightly REPLACE Not enough engagement of stud to col let CHANGE STOP 2 Fault or loose ground connection REPAIR OR TIGHTEN 3 Poor surface condition of base material excessive 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 or deep scribe DO NOT USE CENTER PUNCH OR DEEP SCRIBES 9 Cables too closely coiled 10 Arc blow is evidenced by one side welds In severe cases there will be no melting under one edge of flange while the opposite side is gouged out or appears 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 nar row strips of metal or near edges of sheets or plates In some cases a change in grounding positions or two grounds on the work piece one at each end or edge of work will correct the problem For assis tance in severe cases contact your local sales repre sentative 11 Incorrect plunge setting ADJUST TO PROPER SETTING CID Z12 12 Incorrect spring REPLACE WITH PROPER S
19. of its length whenever pos sible Selecting the proper stop will accomplish this for you The objective of the collet is to maintain a firm grip on the fastener to assure correct alignment and a good electrical connection yet allow for ease of loading 11 1 STANDARD see Figure 5 The standard gun set up is used for welding the majority of applications It consists of the standard adjustable face plate two legs a foot B collet stop and spring for your specific stud size A step by step explanation of the correct way Once the selection of the correct accessory is to set up and operate the standard CD gun made assembly may begin The footpiece is mounted on the legs using 10 32 x 3 4 socket head cap screws inserted through the holes at the base of the footpiece These holes are recessed so that the head of the screws will not protrude To prepare for stud welding it is necessary to have the proper accessories for the stud to be welded Those required are the legs footpiece spring collet and appropriate screws and washers A 3 32 and a 5 32 hex wrench are the only tools Aft bling the 1 d footpiece insert needed for the adjustment of the gun the collet and stop into the open end of the gun shaft Secure the collet in place with two set screws on the shaft Locate the legs with footpiece attached in the holes provided in the gun faceplate It may be necessary to back off the IMPORTANT_ socket scre
20. onsult symbols and related instructions below for necessary actions to avoid the hazards e Henn grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work cable Donottouch electrode if you are in contact with the work ground or another electrode from a different machine Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health e Keep your head out of the fumes Do not breathe the fumes if inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and
21. or positioning of the CD stud is required It is used with the round faceplate and does not re quire a footpiece or legs The adapter is fastened to the faceplate and provides a fixed distance be tween the collet and work The plunge is set by us 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 039 839 1 dia TEMPLATE 099 840 1 25 dia ADAPTER IMPORTANT 18 TO 5 16 I HUSION ROUND FACE PLATE P N 038 722 Figure 7 Template Adapter gun setup CID Z12 11 5 COLLET PROTECTOR BLUNT LEG see Figure 8 The round faceplate with blunt legs can alter nately be used with the collet protector as shown in Figure 8 COLLET PROTECTOR E AS PROTECTOR COLLET INSERT BLUNT LEG 3 REC D P N 033 760 ROUND FACE PLATE P N 033 722 Figure 8 Collet Protector Blunt Leg Setup Page 9 CID Z12 Figure 9 Light Duty CD Gun Page 10 PRO RS 11 6 PARTS LIST LIGHT DUTY CD HANDGUN Part No 300 0100 ITEM PART NO 1 VD oo 1 QN tA A N N N N N N N HF Re Ra HF Feat A 2 A WO N ra O NO WN QN Nn A W N ra 033 384 001 800 033 610 033 799 033 016 033 382 049 955 NOT USED 033 404 033 381 036 496 033 662 25 033 658 25 033 881 033 445 033 447 033 665 033 446 033 608 018 375 016 876 033 757 009 929 016 378 028 83
22. pport or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards t e Im INTERNATIONAL ETR 06 Do not install or place unit on over or near combustible surfaces Do not install unit near flammables e Donot overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas Cylinders or any other accessories Use equipment of adequate capacity to lift and support unit Ifusinglift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce curren
23. s the simplest and most 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 First the gun must be set up with the proper accessories for the length and diameter stud you are going to weld Refer to the CD Accessories Guide and CD Stud Welding Gun Section for information on accessories and gun set up gt Initial Contact During Weld ed Forced Into Molten Pool After Weld FIGURE 1 CONTACT CD WELD The stud is first placed in contact with the base material SEE FIGURE 1 Verify that the gun is held perpendicular to the work Pulling the trigger discharges the capacitors through the stud which va 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 sur 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 ap proximately six milliseconds INTERNATIONAL This technique when equipment is set up properly 1s simple and easily mastered The same power sup ply is capable of welding many different sizes and materials of fasteners If you require assistance in selecting the proper accessories contact our cus tomer service department or your field representa tive 7 0 POWER REQUIREMENTS 110 VOL
24. sed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard 287 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 AWYLELLID INTERNATIONAL Considerations About Welding And The Effects Electric And Magnetic Flelds Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures CID Z12 Keep cables c
25. stant material leather and wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the areais safe before doing any welding Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch fer fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Donot weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current frorn traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire a
26. t contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as butane lighter or matches frorn your person before doing any welding AT FLYING METAL can injure gies Welding chipping wire brushing and grinding cause sparks and flying metal As welds they can throw off slag Wear approved safely glasses with side shields even under your welding helmet CID Z12 BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on qun or torch e Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary su
27. t or reduce duty cycle before starting to weld again Do not block or filter airflow to unit STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury Do not press gun trigger until instructed to do so Do not point gun toward any part of the body other people or any metal when threading welding wire 1 4 Principal Safety Standards Safety i in Welding and Cutting ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference High frequenc
28. the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded WIIGILIDO INTERNATIONAL Arc rays fromthe welding process produce intense visible and invisible ultraviolet and infrared rays that can bum eyes and skin Sparks fly off from the weld e Wearawelding helmet fitted with a proper shade offilter to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resi
29. w in the faceplate to allow Collet Set Screw 2 Ud the legs to enter the hole Center the opening of the footpiece around the weld end of the fastener Tighten the footpiece in position at this time Ad justment for the plunge which is the E j distance the stud protrudes beyond the geg end of the footpiece can now be made This is done by loosening the two 10 32 x 1 4 set screws at the bottom of the faceplate using the 3 32 Allen wrench Then sliding the legs for STD ADJ LEG proper adjustment Refer to the set up ER chart for correct plunge distance from mo ADJUSTABLE 1 8 to 5 16 P N 033 665 NOTE Correct set up on all CD units is 1 8 5 16 plunge This must be assured for proper weld results in all cases Figure 5 Standard Gun Setup Page 7 WIELID INTERNATIONAL 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 diameter Be sure your power source is set for the proper polarity straight for steel reverse for galvanized 11 2 INSTALLING OR CHANGING COLLETS OR CHUCKS The terms collet or chuck are different names for the same device The collet holds the pin or stud to be welded It is secured to the gun shaft by two set screws These screws are loosened to remove or re place a collet Tighten these screws snugly to secure the collet in place When you change the size of the stu
30. y H F can interfere with radio navigation safety services computers and communications equipment Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e If notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained e Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment Such as robots Be sure all equipment in the welding area is electromagnetically compatible Toreduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equioment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compres
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