K.C.D. STUDWELDING CD1000 Instruction Manual Download Page 11

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CD1000 Pin Welder Instruction Manual

K.C.D. Studwelding, Cheltenham, Victoria. Tel: 03 9584 1588, Fax: 03 9584 1688

COMPONENT IDENTIFICATION AND LOCATION GUIDE

Component I.D.

Description

Location

Resistor 470R 2W metal film

PCB

Resistor 470R 1W metal film

PCB

Resistor 22K 3W metal film

PCB

Resistor 220R 2W metal film

PCB

N/A

Resistor 47K 2W carbon film

PCB

Resistor 10R 3W metal film

PCB

N/A

Resistor 220R 1W metal film

PCB

R10

wire link

PCB

R11

N/A

R12

wire link

PCB

R13

Resistor 470R 1W metal film

PCB

R14

Resistor 3K3 10W wire wound

PCB

R15

N/A

R16

Resistor 47R 4W ceramic wire wound

PCB

R17

Resistor 5R 100W wire wound

Machine Base

R18

Resistor 100R 75W wire wound

Machine Base

VR1

Trimpot 10K 10 turn

PCB

VR2

Potentiometer 2K 3W

Front Panel

Capacitor 470uF 25volt electrolytic

PCB

Capacitor 47nF 400volt polyester

PCB

C3 – C4

Capacitor 470uF 25volt electrolytic

PCB

C5 – C8

Capacitor 8,000uF 175volt electrolytic

Machine Base

D1 – D5

Rectifier diode 1N4004

PCB

Zener Diode 10volt 1N5347B

PCB

N/A

Rectifier diode 1N4004

PCB

N/A

D10

Rectifier diode 1N4004

PCB

D11

N/A

Summary of Contents for CD1000

Page 1: ...INSTRUCTION MANUAL CD1000 PIN WELDER K C D STUDWELDING 96A Herald St Cheltenham Victoria 3192 Australia Tel 03 9584 1588 Fax 03 9584 1688 Email info kcdstudwelding com au Web www kcdstudwelding com au ...

Page 2: ...l 03 9584 1588 Fax 03 9584 1688 1 TABLE OF CONTENTS Warranty 2 Safety Precautions 3 CD1000 Pin Welder Components 4 Cable Connections for Welding Pins or Studs 5 Pin Welder Gun 6 How To Use Your CD1000 Pin Welder 7 Appendix 1 Trouble Shooting Guide 9 Appendix 2 Specifications 15 ...

Page 3: ...ects in material or workmanship occur during this period K C D Studwelding reserves the right to repair or replace the defective parts Notice of Claim must be furnished to the manufacturer within ten 10 days after the defect is discovered Return of the defective unit freight prepaid and repair or replacement will be made at no charge to the purchaser K C D Studwelding does not warrant defects in w...

Page 4: ...welding system are dry before proceeding to weld 5 Be sure that cables and connectors are in good condition BUILT IN SAFETY MECHANISM To ensure operator safety the CD1000 Pin Welders are fitted with a quick action Circuit Breaker which operates if a voltage above 30 volts is detected across the output terminals of the welder If such a voltage is detected the Circuit Breaker mains power switch will...

Page 5: ...toria Tel 03 9584 1588 Fax 03 9584 1688 4 CD 1000 PIN WELDER COMPLETE SYSTEM POWER UNIT CONTROLLER WELD GUN CABLES EARTH CLAMP CABLE NOTE Upon receipt of the CD1000 Pin Welder check to see that no damage has been caused in transit and that the welding system is complete ...

Page 6: ...GATIVE EARTH Negative earth connections are recommended when 1 Pin welding to galvanised material 2 Stud welding to plated surfaces 3 When material to be welded is slightly rusty or mill scaled POSITIVE EARTH Positive earth connections are recommended when 1 Welding pins to unplated surfaces NOTE Do not coil cables as inconsistent welds can result ...

Page 7: ...ns of various lengths may be used without any adjustment to the gun head NOTE The nylon chuck guard must be floating freely on the chuck and must not be tightened onto the gun shaft This is because when the pin is forced down onto the work the chuck guard forces back onto the chuck tightening the chuck closed on the weld pin This produces less burning on the pin and hence longer chuck life ...

Page 8: ...ront panel connector marked control cable Make sure the plug is clicked correctly into position NOTE This is a standard setting for welding onto galvanised sheet If you have a different application refer to the recommended polarity on page 5 2 Attach your earth cable to your material to be welded Make sure the clamp is secured tightly 3 Plug your machine into a 240v outlet 4 Turn the voltage contr...

Page 9: ...the gun off the work that you lift the gun straight up until the gun clears the pin This ensures that your welded pin is not bent when you take the gun off the work It also ensures that the copper chuck inside the gun does not get damaged If the chuck becomes loose this can cause burning between the pin and the chuck which is detrimental to the welding process 10 Insert another CD pin and repeat t...

Page 10: ... BY A QUALIFIED TECHNICIAN IT IS HIGHLY RECOMENDED THAT ONLY QUALIFIED TECHNICIANS REMOVE THE COVER OF YOUR CD1000 WELDING UNIT AS CAPACITORS IN THE MACHINE HAVE THE POTIENTIAL TO STORE EXTREMELY DANGEROUS HIGH VOLTAGES WITH OR WITHOUT THE POWER SUPPLY CONNECTED THEREFORE IT IS IMPORTANT THAT THE MACHINE AND THE 240V OUTLET ARE BOTH TURNED OFF If you are not able to have a qualified technician loo...

Page 11: ...wire link PCB R11 N A R12 wire link PCB R13 Resistor 470R 1W metal film PCB R14 Resistor 3K3 10W wire wound PCB R15 N A R16 Resistor 47R 4W ceramic wire wound PCB R17 Resistor 5R 100W wire wound Machine Base R18 Resistor 100R 75W wire wound Machine Base VR1 Trimpot 10K 10 turn PCB VR2 Potentiometer 2K 3W Front Panel C1 Capacitor 470uF 25volt electrolytic PCB C2 Capacitor 47nF 400volt polyester PCB...

Page 12: ...lt 1N5349 POS Weld Terminal D14 Zener Diode 12volt 1N5349B PCB D15 Rectifier diode 1N4004 PCB D16 Rectifier diode skn26 08 Capacitor Bank Q1 N A Q2 Q3 SCR 2N6399 sensitive gate 25amp PCB Q4 NPN transistor 2n3904 PCB Q5 PUT transistor 2N6027 PCB Q6 N A Q7 SCR SKT 340 12E Machine Base RLY1 Relay 12vDC 4PCO PCB RLY2 Relay S1200 A240 0013 Machine Base SW1 Gun trigger switch V 15 3C5 Weld Gun CB1 Circu...

Page 13: ... amp and if the fuse does not blow again check to see that another fault ie shorted weld capacitor C5 C8 has not caused the fault 2 Faulty power lead Check for break in 240 volt supply cable Usually breaks occur where the cable enters the machine PROBLEM 2 WELDER TURNS ON indicator lamp lights BUT NO CHARGE APPEARS ACROSS THE WELD CAPACITORS Possible causes 1 Faulty relay RLY2 If the relay RLY2 ha...

Page 14: ... to the electrolytic capacitors did not blow the fuse the fuse would certainly blow when the weld was made 2 Faulty Relay If contacts RLY1 1 were not opening when weld is made fuse would certainly blow PROBLEM 5 WELDER CHARGES UP BUT WILLNOT WELD Broken wires in cables cause 70 of faults Possible causes 1 Relay will not energise when trigger is pressed a Check that the chuck has not burnt out and ...

Page 15: ...e circuit of SCR Q7 c Check that SCR Q7 has not open circuited PROBLEM 6 WELD EXCESSIVELY HOT REGARDLESS OF VOLTAGE SETTING No control of voltage across weld capacitors Possible Causes 1 Potentiometer VR2 on front panel open circuit 2 Faulty SCR Q2 trigger circuit 3 Faulty SCR Q3 4 Resistors R3 or R6 open circuit PROBLEM 7 VOLTAGE PROTECTION CIRCUIT BREAKER MAIN POWER SWITCH TRIPS WHEN MACHINE IS ...

Page 16: ...steel stainless steel and brass studs Zinc plated and stainless steel pins WEIGHT 15 kg SIZE 315mm x 436mm x 245mm WELDING RATE 15 per minute INPUT POWER 240 V A C WELD MODE Contact CIRCUIT PROTECTION Primary fuses Output voltage circuit breaker operator protection CABLE LENGTH Gun 4 8m 16 Earth 3 04m 10 WELD GUN WEIGHT 0 68 kg 1 5lbs SIZE 11 4 cm x 5 cm x 14 9 cm MATERIAL High strength impact res...

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