Pro-Weld CD-512 Operation Manual Download | Manualshive

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OPERATION/ MAINTENANCE

MANUAL

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Summary of Contents for CD-512

Page 1: ...OPERATION MAINTENANCE MANUAL...

Page 2: ......

Page 3: ...1 1 Standard 8 11 2 Installing or Changing Collets or Chucks 9 11 3 For Weld Pins with Collet Protector 9 11 4 Template Adapter 10 11 5 Collet Protector with Blunt Leg 10 11 6 Parts List HD CD Handgun...

Page 4: ...AYOUT 6 6 STANDARD GUN SETUP 8 7 COLLET PROTECTOR SETUP 9 8 TEMPLATE ADAPTER GUN SETUP 10 9 COLLET PROTECTOR BLUNT LEG SETUP 10 10 HEAVY DUTY CD GUN 11 11 HOT WELD 14 12 COLD WELD 14 13 ARC BLOW 15 14...

Page 5: ...CD 512 PRO WELD...

Page 6: ...CD 512 PRO WELD...

Page 7: ...CD 512 PRO WELD...

Page 8: ...CD 512 PRO WELD...

Page 9: ...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...

Page 10: ...ntrol board for longer life and has been designed for easy main tenance and field service This welder uses standard 110 volt AC line voltage The system comes complete with power cord weld cables and g...

Page 11: ...rials Steel Stainless steel Aluminum Copper Brass Zinc coated Galvanized Weldable Stud Diameter 12 Ga Through 7 16 Weld Base Max W B Dia For AL 5 16 1 4 thread Weld Rate 24 per minute 5 16 Weld Voltag...

Page 12: ...cks 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 un...

Page 13: ...mp 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 it locks...

Page 14: ...ght 4 a contact light 5 and a trigger light 6 on the front panel 3 Before turning the unit ON the voltage control knob 3 should be turned counter clockwise to the lowest setting 4 With all cables conn...

Page 15: ...izes The approximate voltages for each stud size is as follows LOW RANGE 45 60 VDC Min 65 95 VDC 12 ga 95 120 VDC 8 120 145 VDC 10 145 180 VDC 1 4 180 185VDC MAX HIGH RANGE 60 100 VDC 1 4 100 140 VDC...

Page 16: ...tandard 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 to set up and operate the standard CD gun To prepare fo...

Page 17: ...en 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 1 It does not requ...

Page 18: ...tance 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 adapte...

Page 19: ...CD 512 PRO WELD Figure 10 Heavy Duty CD Gun PAGE 11...

Page 20: ...10 033 381 GUN CD DA FA TRIGGER BUTTON MOLDED 1 11 036 496HD GUN FL SHAFT BLOCK A 1 12 033 662 25HD GUN WELD CABLE 25 FT 1 13 033 658 25 GUN CONTROL CABLE 25 FT 1 14 033 881 GUN BODY RH LH STD CD MACH...

Page 21: ...Steel 304 305 Structural Steel Must Be Clean Mild Steel 1008 1018 Stainless Steel 304 305 Brass 65 35 70 30 Aluminum Most alloys of the Aluminum 1100 5356 1100 3000 and 5000 series Zinc Alloys Die Ca...

Page 22: ...le 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...

Page 23: ...er 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 di...

Page 24: ...5 Dropping Resistor 112 0042 6 Transformer 105 0010 7 Fan 102 0014 8 Circuit Breaker 104 0021 9 Charge Bridge 108 0017 10 Discharge Resistor 112 0041 11 Buss Bar 124 0040 12 Safety SCR 108 0042 13 Ch...

Page 25: ...M DESCRIPTION PART NUMBER 14 PC Board 600 0007 15 Buss Bar 124 0042 16 Buss Bar 124 0041 17 Buss Bar 124 0039 18 Diode 108 0005 19 Capacitor 8 106 0001 20 Diode 108 0027 Figure 17 Parts List PAGE 17 1...

Page 26: ...Camlok 3 107 0002 22 2 Pole Female Hubble 107 0031 23 LED Amber Contact 108 0030 24 Knob 102 0060 25 LED Panel Meter 103 0002 26 High Low Range Switch 104 0014 27 Power Switch 104 0013 28 LED Green Re...

Page 27: ...4 C6 C5 OP3 R33 VR1 R38 C3 OP4 R10 R42 R13 R14 R4 D5 D4 D14 V5 V1 V2 V3 OP2 FU3 FU2 V7 V6 C1 C2 R34 D11 R25 R17 R16 R18 R28 R27 D10 R20 R26 R19 D13 R23 R40 R37 C9 D23 R36 D21 D16 R41 R22 R35 D22 D17 D...

Page 28: ...most common problems PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 1 Welder does not turn on A Power connections at Check connections and will not weld Welder or 110 VAC outlet not complete B Broken power...

Page 29: ...er module if shorted 4 Weld is excessively hot A Shorted charge SCR Check with ohmmeter regardless of voltage should not show continuity setting In either direction Replace if shorted B Faulty printed...

Page 30: ...OUND CABLE 2 X 15 2 REQUIRED 125 0101 1 4 MANUAL Operation and Maintenance CD 512 1 5 HEX WRENCH SET 1 19 0 CHECK LIST CD 512 SYSTEM PT NO 100 0111 STANDARD CD 512 WELDING SYSTEM COMPLETE WITH TAPER T...

Page 31: ......

Page 32: ...WELD PRO MANUFACTURED BY MADE IN THE U S A...

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