CD-212P

OPERATION/MAINTENANCE
MANUAL
PRO WELD CD-212P

TABLE OF CONTENTS
1.0 INTRODUCTION 1

2.0 WARRANTY 1

3.0 UNPACKING YOUR UNIT 1

4.0 SUGGESTED SAFETY PRECAUTIONS 1

5.0 GENERAL DESCRIPTION 2

6.0 THE CD WELDING PROCESS 2

7.0 POWER REQUIREMENTS 3

8.0 SYSTEM SPECIFICATIONS 3

9.0 WELDING SYSTEM HOOK-UP 4

9.1 Straight Polarity 4
9.2 Reverse Polarity 5
9.3 Cuphead pin 6

10.0 SYSTEM OPERATION 7

11.0 GUN SET-UP 8

11.1 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 LD CD Handgun 12

12.0 WELDABLE MATERIAL COMBINATIONS 13

13.0 CAUSES OF POOR OR ERRATIC WELDS 14

14.0 TROUBLE SHOOTING POOR WELDS 14

15.0 ROUTINE WELDER MAINTENANCE 15

16.0 ASSEMBLY –CD-212 CONTROLLER 16,17

16.1 PC Board Assembly Drawing 18

17. TROUBLE SHOOTING – ELECTRICAL 19,20

18.0 CHECK LIST CD-212P SYSTEM P.N. 100-0117 21

PRO WELD CD-212P

LIST OF FIGURES
1 CD CONTACT PROCESS 2

2 STRAIGHT POLARITY HOOK-UP 4

3 REVERSE POLARITY HOOK-UP 5

4 CUPHEAD PIN HOOK-UP 6

5 FRONT PANEL LAYOUT 7

6 STANDARD GUN SETUP 8

7 COLLET PROTECTOR SETUP 9

8 TEMPLATE ADAPTER GUN SETUP 10

9 COLLET PROTECTOR/BLUNT LEG SETUP 10

10 LIGHT DUTY CD GUN 11

11 HOT WELD 14

12 COLD WELD 14

13 ARC BLOW 15

14 WELD WITHOUT FOOTPIECE 15

15 GOOD WELD 15

16 PARTS LIST 16

17 PARTS LIST (continued) 17

18 PC BOARD 18
PRO WELD CD-212P
PRO WELD CD-212P
PRO WELD CD-212P
PRO WELD CD-212P
 PRO WELD CD-212P
1.0 INTRODUCTION 3.0 UNPACKING YOUR UNIT
Your new stud welding equipment is carefully Upon receipt of your unit, place it as close as
constructed of the finest components and materials possible to the point of installation before unpacking
available. Used properly, this equipment will give it. Do not operate the unit from an extension power
you years of profitable, efficient service. cord if possible. Once the unit is unpacked it is recom-
The system incorporates the latest in engineer- mended that you inspect it for any physical damage.
ing advances, for completely reliable end welding of Your unit has been completely assembled and
mild steel, stainless steel, aluminum and lead free inspected at the factory. Upon receipt, the unit must be
copper and brass fasteners. hooked up to the recommended incoming power be-
A careful study of this manual will enable you fore welding. We recommend that you check that you
to understand how the welder operates to insure have received all the items listed on the shipping
proper performance under all operating conditions. check list. (see SECTION 18 or 19)
Place the unit in a large enough area to provide
2.0 WARRANTY adequate ventilation. Do not restrict the air flow
The electrical and mechanical components of through the side louvers. Do not allow water to enter
the stud welder are thoroughly performance inspect- the control housing.
ed prior to assembly in the welder. The assembled
welder is completely performance checked. The 4.0 SUGGESTED SAFETY PRECAU-
welder is delivered to you in functional electro-
TIONS
mechanical condition.
In any welding operation, it is the responsibil-
All parts used in the assembly of the welder
ity of the welder to observe certain safety rules to in-
and its accessories are fully warranted for a period of
sure his personal safety and to protect those working
1 YEAR from the date of delivery. In addition, the
near him.
welding capacitors are warranted for a period of 1
Reference is directed, without endorsement or
YEAR from the date of delivery. The printed circuit
recommendation, to ANSI Z49.1, Safety in Welding
boards used in all proweld equipment are warranted
and Cutting, and to AWG Publication A6,1-66, Rec-
for a period of 3 years.
ommended Safety Practices for Gas-Shield Arc Weld-
Under the warranty, the manufacturer reserves
ing.
the right to repair or replace, at their option, defec-
1. Always treat electricity with respect. Under
tive parts which fail during the guarantee period.
open circuit conditions, the welding machine
Notice of any claim for warranty repair or replace-
output voltage may be dangerous.
ment must be furnished to the manufacturer by the
purchaser within ten (10) days after the defect is first
2. Don’t work on live circuits or conductors.
discovered. The manufacturer does not assume any
Disconnect the main power line before check-
liability for paying shipping cost or any labor or ma-
ing the machine or performing any mainte-
terials furnished where such cost are not expressly
nance operations.
authorized in writing.
The manufacturer does not warrant any parts or
3. Be sure the welding machine cabinet is
accessories against failures resulting from misuse,
properly grounded to a good electrical ground.
abuse, improper installation, maladjustment, or use
not in accordance with the operating instructions fur-
4. Don’t stand in water or on a damp floor
nished by the manufacturer. The warranty is valid
while welding or weld in the rain. Avoid wear-
only when studs are purchased from sources ap-
ing wet sweaty cloths when welding.
proved by the manufacturer or are of identical speci-
fications to the manufacturer’s

PAGE 1
 PRO WELD CD-212P
5. Don’t operate with worn or poorly con- The system comes complete with power cord, weld
nected cables. Don’t operate weld gun with cables and gun. Just add the accessories required for
loose cable connections. Inspect all cables fre- the stud size to be welded. This manual should pro-
quently for insulation failures, exposed wires, vide all the information required for you to be able to
loose connections, and repair as needed. set up, weld, and maintain the CD-212 welding sys-
tem.
6. Don’t overload welding cables or continue
to operate with hot cables.
6.0 THE CD WELDING PROCESS
Contact welding is the simplest and most
7. Don’t weld near flammable materials or liq-
common method of CD stud welding. Practically
uids, in or near atmospheres, or on ducts carry-
foolproof, it produces no reverse side marking in
ing explosive gases.
most cases and is suitable for most commercial and
industrial applications.
8. Don’t weld on containers which have held
First, the gun must be set-up with the proper
combustible or flammable materials, or on ma-
accessories for the length and diameter stud you are
terials which give off flammable or toxic va-
going to weld. Refer to the CD Accessories Guide
pors when heated, without proper cleaning,
and CD Stud Welding Gun Section for information
purging, or inerting.
on accessories and gun set-up.
9. Be sure to provide for proper ventilation
when welding in confined spaces. 1 2

10. Never look at the electric arc without wear-

ing protective eye shields.
Initial Contact During Weld
11. Always use the proper protective clothing,
gloves, ect. 3 4

12. Never strike an arc when near a bystander

who is unaware of the dangers of ultraviolet
light on their eyes.
Forced Into Molten Pool After Weld

5.0 GENERAL DESCRIPTION (FIGURE 1 CONTACT CD WELD)

CD-212 HEAVY DUTY PORTABLE
CD STUD/PIN WELDER The stud is first placed in contact with the
base material (SEE FIGURE 1). Verify that the gun is
The CD-212 portable CD welder is a self con- held perpendicular to the work. Pulling the trigger
tained heavy duty capacitor discharge power supply discharges the capacitors through the stud which va-
capable of welding up to 1/4” flanged studs in mild porizes the tip. The proper tip design is critical. This
steel. is what determines the length of time of the weld. An
The CD-212 utilizes a solid state control board arc is briefly sustained which melts the stud base sur-
for longer life and has been designed for easy face and the work surface directly underneath the
maintenance and field service. This welder uses stud. The spring pressure in the gun then forces the
standard 110 volt AC line voltage. stud into the molten pool, completing the weld in ap-
proximately six milliseconds.

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 PRO WELD CD-212P
This technique, when equipment is set up properly, Weld Mode:
is simple and easily mastered. The same power sup- Contact
ply is capable of welding many different sizes and Polarity:
materials of fasteners. If you require assistance in Straight or Reverse
selecting the proper accessories, contact our custom- Power Required:
er service department or your field representative. 110 Volt AC 60 Hz 20 Amp
Circuit Protection:
7.0 POWER REQUIREMENTS 15 Amp circuit breaker
110 VOLT OPERATION 3AG 1 Amp 250 volt fuses
110 volt AC 60 H: 20 amps; (2 on PC Board)
Circuit protection: 15 amp circuit breaker
(P/N: 104-0020) STANDARD GUN & CABLE SPECIFICATIONS
Integral 9 foot power cord
IF EXTENSION REQUIRED WELD GUN-LIGHT DUTY CD CONTACT
Cable Length 110 Volt
12’ #16/3 Part Number:
25’ #16/3 300-0100 B Collet Gun
30’ #14/3 300-0101 Taper Tip Gun
50 #12/3 Weight:
2 lbs. (not including cable)
8.0 SYSTEM SPECIFICATIONS ( lbs. (including 25 ft. #4 weld cable & 16-4
Weight: SOW control cable)
26 Lbs. Size:
Size: 6 1/2” x 5 3/4” x 2”
9” W x 11 3/4” D x 8 1/2” H Weldable Stud Diameter:
22.9 cm W x 29.8 cm D x 21.6 cm H 14 Ga. Through 1/4” Flanged
Chassis: Material:
14 Ga. Aluminum (Painted International High strength, impact resistant, glass fiber re-
Orange) inforced polycarbonate
Panel Controls: Integral Gun Cable Length:
Power 25 feet – #4 AWG
Voltage Controls Connectors:
Weldable Materials: Male Camlok / 2 Pin Hubbell Male
Steel, Stainless steel, Aluminum, Copper,
Brass, Zinc coated, Galvanized Cables
Weldable Stud Diameter:
14 Ga. Through 1/4” Flanged Ground Cable:
(Max W.B. Dia. For AL=5/16” (1/4” thread) (1) #4 x 15’ (P/N: 125-0100)
Weld Rate:
12 per minute
Weld Voltage:
45-200 VDC
Capacitance:
66,000 uF nominal

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 PRO WELD CD-212P

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.

3
1

3A

1A 4A

2
5

Figure 2 Straight Polarity Hook-Up

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PRO WELD CD-212P

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 “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 GROUND (1). 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.

3
4

3A

1A
4A

2
5

Figure 3 Reverse Polarity Hook-Up

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 PRO WELD CD-212P

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

A. Connect ground cable connector (1A) into camlok (1). The camlok should be connected into the
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 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.

3
1

3A

4A
1A

2
5

Figure 4 Cuphead Pin Hook-Up

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 PRO WELD CD-212P
10.0 SYSTEM OPERATION
(see Figure 4)

1. The CD-212 is designed for simple, yet precise operation.

2. 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

2 1 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
80-120 VDC #8
Figure 5 Front Panel Layout
120-160 VDC #10
160-190 VDC 1/4”
200VDC MAX.

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 PRO WELD CD-212P

11.0 GUN SET-UP

For CD welding, the stud normally should be
11.1 STANDARD (see Figure 5)
engaged for all but 1/4” of its length, whenever pos-
sible. Selecting the proper stop will accomplish this
The standard gun set-up is used for welding the
for you. The objective of the collet is to maintain a
majority of applications. It consists of the standard
firm grip on the fastener to assure correct alignment
adjustable face plate, two legs, a foot, B-collet, stop,
and a good electrical connection, yet allow for ease
and spring for your specific stud size.
of loading.
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 mount-
ed on the legs using 10-32 x 3/4” socket head cap
To prepare for stud welding, it is necessary to
screws, inserted through the holes at the base of the
have the proper accessories for the stud to be weld-
footpiece. These holes are recessed so that the head
ed. Those required are the legs, footpiece, spring,
of the screws will not protrude.
collet, and appropriate screws and washers. A 3/32”
and a 5/32” hex wrench are the only tools needed for
After assembling the legs and footpiece, insert
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 sock-
et screw in the faceplate to allow 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
distance the stud protrudes beyond the
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 prop-
er adjustment. Refer to the set-up chart
for correct plunge distance (from 1/8”
to 5/16”).
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 6 Standard Gun Setup

PAGE 8
 PRO WELD CD-212P
The gun is now ready to weld. Select the prop- 1. It does not require a pin stop.
er setting for the size stud to be welded. Voltage is therefore, the same setup is applicable
determined by the weld base diameter. Be sure your for a range of pin lengths.
power source is set for the proper polarity: straight
for steel, reverse for galvanized. 2. There is a fixed plunge, no gun
adjustments necessary.
11.2 INSTALLING OR CHANGING COLLETS
OR CHUCKS 3. It provides stability at the weld end
of the pin.
( The terms collet or chuck are different names for
the same device). The collet holds the pin or stud to There are two standard sizes available: 12 ga.
be welded. It is secured to the gun shaft by two set And 10 ga. It is used with the round faceplate and
screws. These screws are loosened to remove or re- three blunt legs. The collet protector slides over the
place a collet. Tighten these screws snugly to secure collet and fastens to the chuck with three allen set
the collet in place. screws. The insert, which takes the place of the In-
teral stop, is replaceable.
When you change the size of the stud you are
welding, you must also change to the appropriate The stud is pushed into the chuck until the flange bot-
collet. If a collet becomes damaged or broken, it toms out on the insert. The collet protector is not
must be replaced. You may also need a stop. available for studs larger than 10 ga.
11.3 GUN SET-UP FOR WELD PINS WITH The standard adjustable legs and footpiece
COLLET PROTECTOR (see Figure 6) combination can alternately be used with the collet
protector as shown in Figure 10.
The collet protector has several advantages
over the standard set-up.

Figure 7 Collet Protector Gun Setup

PAGE 9
 PRO WELD CD-212P
11.4 TEMPLATE ADAPTER (see Figure 7) 11.5 COLLET PROTECTOR/BLUNT LEG
(see Figure 8)
The template adapter is used when precise
location or positioning of the CD stud is required. The round faceplate, with blunt legs, can alter-
It is used with the round faceplate and does not nately be used with the collet protector as shown in
require a footpiece or legs. The adapter is fastened Figure 8.
to the faceplate and provides a fixed distance be-
tween the collet and work. The plunge is set by
using 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 siz-

es, (1” and 1-1/4” diameter).

Figure 9 Collet Protector/Blunt Leg Setup

Figure 8 Template Adapter gun setup

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PRO WELD CD-212P

PAGE INTENTIONALLY LEFT BLANK

 PRO WELD CD-212P

Figure 10 Light Duty CD Gun

PAGE 11
 PRO WELD CD-212P
11.6 PARTS LIST LIGHT DUTY CD HANDGUN
Part No. 300-0100

ITEM PART NO. DESCRIPTION QTY

1 033-384 GUN (CD) REAR CAP MOLDED 1
2 001-800 SPRING MAIN HEAVY SILVER 1
3 033-610 GUN (CD/DA) BEARING ASSEMBLY 1
4 033-799 GUN (CD) SHAFT TUBE 1
5 033-016 HEX HEAD CAP SCREW 3
6 033-382 GUN (CD/DA/FA) TRIGGER SPRING 1
7 049-955 M SCREW SET MS, BRASS PLT 2
8 NOT USED GUN (CD/DA/FA) CABLE CLAMP (ALUM. BLOCK) 1
9 033-404 TRIGGER SWITCH 1
10 033-381 GUN (CD/DA/FA) TRIGGER BUTTON MOLDED 1
11 036-496 GUN (FL) SHAFT BLOCK – A 1
12 033-662-25 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 MACHINED 1
15 033-445 GUN (CD/FL) SHAFT BOOT ASSY 1
16 033-447 GUN (CD) SHAFT BOOT RETAINING RING 1
17 033-665 GUN (CD) FACEPLATE – STD. ADJUSTABLE 1
18 033-446 GUN (CD) SHAFT BOOT SNAP RING 1
19 033-608 GUN (CD) WELD PIGTAIL ASSY 1
20 018-375 SCREW PAN HEAD 2
21 016-876 WASHED, LOCK INTO. TOOTH 1
22 033-757 LEG (CD) STD.ADJ. 7” 2 REF.
23 009-929 FLAT WASHER 2 REF.
24 016-378 SOCKET HEAD CAP SCREW 2 REF.
25 028-833 STD. FOOTPIECE 1 REF.

PAGE 12
 PRO WELD CD-212P

12.0 WELDABLE MATERIAL COMBINATIONS

BASE MATERIAL STUD MATERIALS

Mild Steel (1008-1018) Mild Steel 1008, 1018

Stainless Steel 304, 305
Brass 65-35, 70-30
Copper, Silicon/Bronze

Galvanized Sheet (duct-”Q” Decking Mild Steel 1008-1018

Stainless 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 Cast) Aluminum 1100, 5356

Medium Carbon Steel (1030-1018) Mild Steel 1008, 1018

Stainless Steel 304,305
Brass 65-35, 70-30

Lead Free Brass Mild Steel 1008, 1018

Lead Free Rolled Brass Stainless Steel 304, 305
Electrolytic Copper Copper, Silicon/Bronze

PAGE 13
 PRO WELD CD-212P
13.0 CAUSE OF POOR OR ERRATIC 12. Incorrect spring. (REPLACE WITH PROPER
WELDS SPRING)

1. Loose collet. Does not grip stud tightly. 13. Poor stud quality.
(REPLACE) Not enough engagement of stud to col-
let. (CHANGE STOP) 14.0 TROUBLE SHOOTING POOR
WELDS
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)

Figure 11 Weld too Hot
6. Dirt in gun. (CLEAN)
Weld too Hot
7. Incorrect polarity. (CABLES HOOKED-UP
WRONG) A) Decrease voltage.
B) Decrease capacitance.
8. Use of center punch or deep scribe. (DO NOT C) Increase stud protrusion.
USE CENTER PUNCH OR DEEP SCRIBES) D) Increase spring pressure.

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 Figure 12 Weld too Cold
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- Weld too Cold
sentative.
A) Increase voltage.
11. Incorrect plunge setting. (ADJUST TO PROPER B) Increase capacitance.
SETTING) C) Decrease stud protrusion.
D) Decrease spring pressure.

PAGE 14
 PRO WELD CD-212P
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
Figure 13 Arc Blow may break the cables. Don’t use the cables as a “tow
line” to move the control. Avoid damage or straining
Arc Blow the cables where they enter the gun or at the connect-
ors.
A) Use double grounds.
B) Ground too close or not spaced 2. It is good practice to occasionally remove
evenly. 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.
Figure 14 Weld without footpiece

Weld without footpiece

3. While the cover is removed, tighten all the
A) Use standard footpiece. weld cable connections and make sure all the screws
B) Use template adapter. on the capacitor terminals are torque to 30 inch-
C) Use tripod blunt legs. pounds.

NOTE:
Keep the gun free of
dust, dirt or foreign
material

Figure 15 Good Weld

PAGE 15
PRO WELD CD-212P
16.0 ASSEMBLY CD-212P CONTROLLER (see Figur e 16,17, & 18)

13 12 11 10 9 8
14

14a

7
15

1 6

2 3
4 5

Figure 16 Parts List

ITEM DESCRIPTION PART NUMBER
1 Chassis 101-0030
2 SCR Mounting 124-0026
3 Main SCR 108-0001
4 Capacitor (3) 106-0023
5 Transformer 105-0017
6 PC Board 600-0013
7 Discharge Resistor 112-0041
8 Safety Discharge SCR 108-0042
9 Charging SCR 108-0002
10 Buss Bar 124-0034
11 Diode 108-0027
12 Charging Bridge 108-0017
13 Buss Bar 124-0035
14 Nichrome Resister 112-0066
14a 150K 25W Pot 111-0002
15 Fan 102-0012

PAGE 16
 PRO WELD CD-212P

21 20

16
19

18 17

Figure 17 Parts List

ITEM DESCRIPTION PART NUMBER

16 Knob 102-0060
17 Female Camlok (2) 107-0002
18 2-Pole Female Hubbell 107-0031
19 Power Switch 104-0013
20 Circuit Breaker 104-0020
21 Fan Guard 102-0039

PAGE 17
 PRO WELD CD-212P
16.1 PC BOARD ASSEMBLY DRAWING
FU1 and FU2 are 3AG 1 ampere fuses

V4 R11

R13
+

R9
C4 ZD1

R6
R7
R10

C2
R23
R8 C1 V1

+ R17 C5
R14

V6 C7 R5
ZD2
R15

D7

D6 +
R21 R4 V2
R16 V3
D2
R22 R12
R18 D1
C6 + V5
R20 D5 R3

D4
OP3 OP2 D3
R25
OP1 R2
+ C8 R26
D10 D12
D9 R24 R19 D11 D13
C3 D8
R1

F2 F1

Figure 18 PC Board

PAGE 18
 PRO WELD CD-212P

17.0 TROUBLE SHOOTING – ELECTRICAL

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 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 cable or Check wires for continuity.

loose wire connection in Repair break.
the plug.

C. Fuse blown. Replace fuse.

2. Fuse blows each time *A. Shorted weld capacitor. Check safety vent seal for
unit is turned on. Rupture hole. Replace
defective capacitor.

B. Shorted rectifier (BR1) Check for a short across the

rectifier with ohmmeter.
Replace rectifier module if
shorted.

C. Incorrect primary hookup. Check transformer connections.

D. Shorted transformer Replace transformer.

assembly.

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 PRO WELD CD-212P
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

3. Welder turns on but A. Ground cable connections Check for continuity

does not operate not complete.

*B. Broken gun control cable Check continuity between

or loose wire connection pins on control plug while
in the plug. Shorted or trigger is depressed.
open trigger switch. Should read continuity.

*C. Faulty printed circuit Replace with new PC

board. Board.

D. Shorted weld SCR. Check with ohmmeter

(should not show continuity
in either direction). Replace
rectifier 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 circuit Replace with new PC

board. Board.

C. Open voltage Replace defective voltage

potentiometer. Potentiometer.

5. Poor and erratic A. Improper gun setup. Check applicable gun setup
welding. Instruction page.

B. Improper grounding or Check applicable cable setup

cable setup or incorrect Instruction page.
polarity.

C. Weld cables are coiled. Straighten out cables.

D. Incorrect voltage setting. Adjust as necessary.

E. Studs or pins not Adjust legs as necessary.

perpendicular to work Replace defective legs.
surface.

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 PRO WELD CD-212P
18.0 CHECK LIST CD-212P SYSTEM PT. NO. 100-0117

STANDARD CD-212P WELDING SYSTEM COMPLETE WITH B-COLLET GUN

AND 25’ #4 GROUND CABLE

ITEM DESCRIPTION PART # QTY

1. CD-212P CONTROLLER 110 VAC 200-0025 1
2. GUN ASSY. B-COLLET w/INTEGRAL 25 FT.WELD
& CONTROL CABLE 2-LEGS, and FOOTPIECE 300-0100 1
3. GROUND CABLE #4 X 15’ 125-0100 1
4. MANUAL, Operation and Maintenance CD-212 1
5. HEX WRENCH SET 1

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MANUFACTURED BY
PRO WELD

MADE IN THE U.S.A.