CAPACITOR DISCHARGE STUD WELDING SYSTEMS

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1 CAPACITOR DISCHARGE STUD WELDING SYSTEMS ARE complete stud welding systems which weld CD studs using the CD stud welding process. CONSIST OF the following items: A CD stud welding Power Supply/Controller A CD stud welding hand Gun* A system Power Cable A system Ground Cable A gun Extension Cable Set *The gun requires additional accessories depending on the part to be welded and its application. ARE GENERALLY USED FOR WELDING: Small diameter studs (up to 3/8 diameter: When base material is thin (28ga. To 18ga.) When reverse side marking of welded part is not permissible When reverse side of welded part is painted or laminated When warpage or excessive heating of the welded part is not permissible When welding dissimilar metals See page 13-2 to help you select the stud welding system to meet your CD stud welding requirements. Houston, Texas

2 CD STUD WELDING SYSTEM SELECTION GUIDE WHEN YOU REQUIRE THIS CD STUD/PIN WITH THIS DIAMETER AND IN THIS MATERIAL CD 440 THESE SYSTEMS CAN MEET YOUR REQUIREMENTS SUNBELT PRO-WELD CD 660 CD 880 CD 1320 CD-212 CD-212P CD-312 CD GA. MS & SS CD PINS AL GA. MS & SS AL 1100 CUPHEADS 12 GA. MS & SS #4, #6, #8, #10 MS & SS AL1100,5000 AL 6061 CDF 1/4 MS & SS AL1100,5000 AL6061 5/16 MS & SS AL 3/8 MS & SS CDSF #4, #6, #8, #10 1/4 5/16 3/8 AL MS & SS AL 1100,5000 AL 6061 MS & SS AL 1100,5000 AL 6061 MS & SS AL MS & SS AL CDNF (all) Please submit your request along with sample parts to Sunbelt Stud Welding, Inc. for Feasibility testing and recommendations. NOTE: This chart is only a quick-reference guide, and the stud size ranges shown are general. With special modifications, or set-ups, these systems may exceed the limits shown for certain applications. Full capability Limited and requires spring. Recommended Lift Gun Limited Houston, Texas

3 CD WELDERS: CD 440 DESCRIPTION/FEATURES The SUNBELT 440 is a compact stud welding unit for capacitor discharge stud welding Welding materials: steel (unalloyed and alloyed), aluminum, brass, weldable special alloys Highest operational reliability and simple handling Excellent welding quality, high power - on time Quick welding sequences through short charging times Digital display of charging voltage All important functions indicated by LED Short charging time and thus quick welding sequences through electronically clocked inverter charging board Low-loss charging of capacitors through electronically clocked inverter charging board Continuously adjustable charging voltage Charging voltage not influenced by supply voltage variations Optimal safety during welding through integrated safety switching Light and handy, especially suitable for mobile use Compact construction, low weight Robust, powder coated metal housing Powder coated front-plate with screen print (scratch and abrasion-resistant), ensures longtime readability of all labeling Dimensions: 8 W x 10.5 H x 16 L Welding Time: 1 to 3 msec. Weight: 22 lb. Stud Range: 14GA to 1/4 Capacitance Charge: 44,000 mfd Weld Rate: up to 25 Studs per minute Charging Voltage: V (adjustable) Input Power: 230/115 V, 50/60 Hz, 10 AT PART LIST System Complete B-S1196 Gun Only (PKM-1B) B Power Unit Only B Ground Cable B Houston, Texas

4 CD WELDERS: CD 660 DESCRIPTION/FEATURES The SUNBELT CD 660 is a compact stud welding unit for capacitor discharge stud welding Welding materials: steel (unalloyed and alloyed), aluminum, brass, weldable special alloys Highest operational reliability and simple handling Excellent welding quality, high power - on time Quick welding sequences through short charging times Digital display of charging voltage All important functions indicated by LED Short charging time and thus quick welding sequences through electronically clocked inverter charging board Low-loss charging of capacitors through electronically clocked inverter charging board Continuously adjustable charging voltage Charging voltage not influenced by supply voltage variations Optimal safety during welding through integrated safety switching Light and handy, especially suitable for mobile use Compact construction, low weight Robust, powder coated metal housing Powder coated front-plate with screen print (scratch and abrasion-resistant), ensures longtime readability of all labeling Dimensions: 8 W x 10.5 H x 16 L Welding Time: 1 to 3 msec. Weight: 24 lb. Stud Range: 14GA to 5/16 Capacitance Charge: 66,000 mfd Weld Rate: up to 25 Studs per minute Charging Voltage: V (adjustable) Input Power: 230/115 V, 50/60 Hz, 10 AT PART LIST System Complete B-S2013 Gun Only (PKM-1B) B Power Unit Only B Ground Cable B Houston, Texas

5 CD WELDERS: CD 880 DESCRIPTION/FEATURES The SUNBELT CD 880 is a high performance stud welding unit for capacitor discharge stud welding Welding materials: steel (unalloyed and alloyed) aluminum, brass, weldable special alloys Highest operational reliability and simple handling; excellent welding quality, high power on time Quick welding sequences through short charging times Ideally suitable for difficult welding tasks Optional with automatic module to control an automatic stud feeding system and automatic welding gun or head (automatic module can be retrofitted) Digital display of charging voltage All important functions indicated by LED Short charging time and thus quick welding sequences through electronically clocked inverter charging board (standard: 1 charging board, optional: 2 charging boards) Low-loss charging of capacitors through electronically clocked inverter charging board Continuously adjustable charging voltage Optimal safety during welding through integrated safety switching Robust, powder-coated metal housing and powder-coated front plate with screen print (scratch & abrasion resistant) ensures longtime readability of all labeling Dimensions: 11 W x 10 H x 18.5 L Welding Time: 1 to 3 msec. Weight: 42 lb. Stud Range: 14GA to 3/8 Capacitance Charge: 88,000 mfd Weld Rate: up to 40 Studs per minute Charging Voltage: V (adjustable) Input Power: 230/115 V, 50/60 Hz (±10%) PART LIST System Complete B-S2007 Gun Only (PKM-1B) B Power Unit Only B Ground Cable B Houston, Texas

6 CD WELDERS: CD 1320 DESCRIPTION/FEATURES The SUNBELT CD1320 is a compact stud welding unit for capacitor discharge stud welding Welding materials: steel (unalloyed and alloyed), aluminum, brass, weldable special alloys Highest operational reliability and simple handling Excellent welding quality, high power - on time Quick welding sequences through short charging times Ideally suitable for difficult stud welding tasks Optional with automatic module to control an automatic stud feeding system and an automatic welding gun or an automatic welding head (automatic module can be retrofitted) Digital display of charging voltage All important functions are indicated and controlled by LED Short charging time and thus quick welding sequences through electronically clocked inverter charging board (standard: 1 charging board, optional: 2 charging boards) Low-loss charging of capacitors through electronically clocked inverter charging board Continuously adjustable charging voltage Charging voltage not influenced by supply voltage variations Optimal safety during welding through integrated safety switching Robust, powder-coated metal housing and powder-coated front plate with screen print (scratch & abrasion resistant) ensures longtime readability of all labeling Dimensions: 11 W x 10.5 H x 18.5 L Welding Time: 1 to 3 msec. Weight: 46 lb. Stud Range: 14GA to 3/8 Capacitance Charge: 132,000 mfd Weld Rate: up to 40 Studs per minute Charging Voltage: V (adjustable) Input Power: 115/230 V, 50/60 Hz (± 10%) PART LIST System Complete B-S2014 Gun Only (PKM-1B) B Power Unit Only B Ground Cable B Houston, Texas

7 CD WELDERS: CD-212 DESCRIPTION The CD-212 is a state-of the-art solid state capacitor discharge stud/pin welder. Its lightweight design increases portability but with the power to weld 1/4 diameter flanged studs. The extremely short weld time of capacitor discharge process allows studs to be welded to material as thin as.015 without burn-through. The unit is capable of welding mild steel, stainless and aluminum studs. Dimensions: 8-1/2 H x 9 W x 11-3/4 D Mode: Contact Gap (optional) Weight: 26 lb. Stud Range: 14 Ga. 1/4 Capacitance Charge: 66,000 mfd Weld Rate: 12 Studs per minute Range: VDC Input Power: 110 VAC, 60 Hz, 20 AMPS PARTS LIST System Complete Gun Only Power Unit Only Ground Cable FEATURES Designed and built in the U.S.A. Safety Fault Shut Down Light Weight Recessed Control Panel Circuit Breaker Protection Houston, Texas

8 CD WELDERS: CD-212P DESCRIPTION The CD-212P is a state-of the-art solid state capacitor discharge stud/pin welder. Its lightweight design increases portability but with the power to weld 1/4 diameter flanged studs. The extremely short weld time of capacitor discharge process allows studs to be welded to material as thin as.015 without burn-through. The unit is capable of welding mild steel, stainless, aluminum studs, and cuphead pins. Dimensions: 8-1/2 H x 9 W x 11-3/4 D Mode: Contact Weight: 26 lb. Stud Range: 14 Ga. 1/4 Capacitance Charge: 66,000 mfd Weld Rate: 12 Studs per minute Range: VDC Input Power: 110 VAC, 60 Hz, 20 AMPS PARTS LIST System Complete Gun Only Power Unit Only Ground Cable FEATURES Designed and built in the USA Safety Fault Shut Down Light Weight Recessed Control Panel Circuit Breaker Protection 6381 Windfern Road Houston, Texas

9 CD WELDERS: CD-312 DESCRIPTION The CD-312 is a state-of the-art solid state capacitor discharge stud/pin welder. Its rugged design and user friendly controls make it simple to set up and use. The extremely short weld time of capacitor discharge process allows studs to be welded to material as thin as.015 without burn-through. The unit is capable of welding mild steel, stainless, and aluminum studs. Dimensions: 8-1/2 H x 10 W x 16-1/2 D Mode: Contact Gap (optional) Weight: 48 lb. Stud Range: #2-5/16 Capacitance Charge: 84,000 mfd Weld Rate: 24 Studs per minute Range: VDC Input Power: 110 VAC, 20 AMPS PARTS LIST System Complete Gun Only Power Unit Only Ground Cable FEATURES Designed and built in the USA Safety Fault Shut Down L.E.D. Panel Meter Recessed Control Panel Diagnostic L.E.D. s Houston, Texas

10 CD WELDERS: CD-512 DESCRIPTION The CD-512 is a state-of the-art solid state capacitor discharge stud welder. Its rugged design and user friendly controls make it simple to set up and use. The extremely short weld time of the capacitor discharge process allows studs to be welded to material as thin as.015 without burn-through. The unit is capable of welding mild steel, stainless, and aluminum studs. Dimensions: 8-1/2 H x 13-1/4 W x 20 D Mode: Contact Gap (optional) Weight: 64 lb. Stud Range: #2-3/8 Capacitance Charge: 84, ,000 mfd Weld Rate: 24 Studs per minute Charge Range: VDC Input Power: 110 VAC, 20 AMPS PARTS LIST System Complete Gun Only Power Unit Only Ground Cable FEATURES Designed and built in the USA Safety Fault Shut Down L.E.D. Panel Meter Recessed Control Panel Diagnostic L.E.D. s Houston, Texas

11 CD WELDERS: CD TABLE TOP Table Size: Weight: 22 W x 18 Deep x 24 H (Max. Ext.) 115 lbs. CONSTRUCTION Table Top: Base: Cast Aluminum 16 Ga. Steel Painted Front Panel Controls: Two palm type weld buttons, Adjustable pneumatic controls for weld pressure. Welding Material: Mild steel, stainless, aluminum, copper, brass Weld Mode: Contact/Gap Requirements: 120 Volt AC 50/60 Hz, 10 Amp Additional Controls: Time delay before weld (no delay in gap mode) Welding Diameters: Dependent on power supply/controller used for welding. Polarity: Straight or reverse Air Requirements: 80 PSI, filtered and dry air Houston, Texas

12 CD WELDERS: CD-1000 DESCRIPTION/FEATURES The CD1000 is a cost effective standard stud welding unit. It is suitable for tip ignition with contact (CD studs and cuphead pins). The CD1000 is compact with a strong metal housing to withstand rough conditions. It is specially designed for welding CD studs and cuphead pins with the same adjustment (no spring pressure adjustment, no change of spring one gun for two applications). It will weld mild steel, stainless, aluminum and brass CD studs. The CD1000 s many features include: operation at high voltage fluctuations (-25% up to +20%); integrated mains filter; high-tech microcontroller to guarantee precise process control, safest operating conditions and highest operating comfort; stepless voltage regulation; error code indication by LED indications; easy control of all functions by LED indications; easy change of polarity of welding voltage by interchanging welding current cable and ground cable (if required); transformer temperature control automatic shut-off at overheat; highest safety standard by automatic control of SCR and contact to work piece; recorded high voltage test; EMC-tested. Dimensions: L x 7.48 W x 9.45 H Welding Time: 4 to 7 msec. Weight: lb. Stud Range: (#4 to 1/4 ) (Cuphead mode 14 Ga. To 10 Ga.) Capacitance Charge: 66,000 mfd Weld Rate: 6 to 15 Studs per minute Charging Voltage: V (stepless) Input Power: 230/115 V, 50/60 Hz, 10 AT PARTS LIST System Complete All Gun Only Power Unit Only Ground Cable Houston, Texas

13 CD WELDERS: CD-1501 DESCRIPTION/FEATURES The CD1501 is a cost-effective standard capacitor discharge stud welding unit. It is suitable for tip ignition with contact and gap. The CD1501 is compact with a strong metal housing. It will weld mild steel, stainless, aluminum and brass CD studs. The CD1501 s many features include: operation at high voltage fluctuations (-25% up to 20%); integrated mains filter; high-tech microcontroller to guarantee precise process control, safest operating conditions and highest operating comfort; stepless voltage regulation (charging and discharge); automatic discharge of capacitors by reducing the loading voltage; easy and reproducible setting of the loading voltage/welding energy by digital display; library function automatic adjustment of the loading voltage by selecting the stud diameter (fine adjustment by pushing arrow key); error code indication by digital display; easy control of all functions by LED indications; easy change of polarity of welding voltage by interchanging welding current cable and ground cable (if required); electronically protected magnetic circuit when using gap gun CA-08; temperature controlled cooling fan reduces contamination inside the power unit (high reliability) and reduces noise; temperature control of transformer and interior of power unit automatic shut off at overheat; highest safety standard by automatic control of SCR and contact to work piece; recorded high voltage test; EMC-tested. Dimensions: 16.5 L x 7.1 W x 9.8 H Welding Time: 1 to 3 msec. Weight: 37 lb. Stud Range: (#4 to 5/16 ) (14 Ga. to 5/16 ) Capacitance Charge: 66,000 mfd Weld Rate: 8 to 20 Studs per minute Charging Voltage: V (stepless) Input Power: 230/115 V, 50/60 Hz, 10 AT PARTS LIST System Complete All Gun Only (C08) Power Unit Only Ground Cable Houston, Texas

14 CD WELDERS: CD-2301 DESCRIPTION/FEATURES The CD2301 is a cost-effective standard capacitor discharge stud welding unit. It is suitable for tip ignition with contact and gap. The CD2301 is compact with a strong metal housing. It will weld mild steel, stainless, aluminum and brass CD studs. The CD2301 s many features include: operation at high voltage fluctuations (-25% up to 20%); integrated mains filter; high-tech microcontroller to guarantee precise process control, safest operating conditions and highest operating comfort; stepless voltage regulation (charging and discharge); automatic discharge of capacitors by reducing the loading voltage; easy and reproducible setting of the loading voltage/welding energy by digital display; library function automatic adjustment of the loading voltage by selecting the stud diameter (fine adjustment by pushing arrow key); error code indication by digital display; easy control of all functions by LED indications; easy change of polarity of welding voltage by interchanging welding current cable and ground cable (if required); electronically protected magnetic circuit when using gap gun CA-08; temperature controlled cooling fan reduces contamination inside the power unit (high reliability) and reduces noise; temperature control of transformer and interior of power unit automatic shut off at overheat; highest safety standard by automatic control of SCR and contact to work piece; recorded high voltage test; EMC-tested. Dimensions: 20 L x 7.1 W x 9.8 H Welding Time: 1 to 3 msec. Weight: 46 lb. Stud Range: (#4 to 5/16 ) Capacitance Charge: 99,000 mfd Weld Rate: 8 to 20 Studs per minute Charging Voltage: V (stepless) Input Power: 230/115 V, 50/60 Hz, 10 AT PARTS LIST System Complete All Gun Only (C08) Power Unit Only Ground Cable Houston, Texas

15 CD WELDERS: CD-3101 DESCRIPTION/FEATURES The CD3101 is a cost-effective standard capacitor discharge stud welding unit. It is suitable for tip ignition with contact and gap. The CD3101 is compact with a strong metal housing. It will weld mild steel, stainless, aluminum and brass CD studs. The CD3101 s many features include: operation at high voltage fluctuations (-25% up to 20%); integrated mains filter; high-tech microcontroller to guarantee precise process control, safest operating conditions and highest operating comfort; stepless voltage regulation (charging and discharge); automatic discharge of capacitors by reducing the loading voltage; easy and reproducible setting of the loading voltage/welding energy by digital display; library function automatic adjustment of the loading voltage by selecting the stud diameter (fine adjustment by pushing arrow key); error code indication by digital display; easy control of all functions by LED indications; easy change of polarity of welding voltage by interchanging welding current cable and ground cable (if required); electronically protected magnetic circuit when using gap gun CA-08; temperature controlled cooling fan reduces contamination inside the power unit (high reliability) and reduces noise; temperature control of transformer and interior of power unit automatic shut off at overheat; highest safety standard by automatic control of SCR and contact to work piece; recorded high voltage test; EMC-tested. Dimensions: 20 L x 7.1 W x 9.8 H Welding Time: 1 to 3 msec. Weight: 48 lb. Stud Range: (#4 to 3/8 ) Capacitance Charge: 132,000 mfd Weld Rate: 8 to 20 Studs per minute Charging Voltage: V (stepless) Input Power: 230/115 V, 50/60 Hz, 10 AT PARTS LIST System Complete All Gun Only (C08) Power Unit Only Ground Cable Houston, Texas

16 SUNBELT BATTERY UNIT W/BATTERY OR 110 V A/C PEGASAR 500 accu Optional Extra Battery Optional Stand Alone Charger Power unit w/battery and built in charger *******BATTERY OR 110 VOLT******* DESCRIPTION/FEATURES The Pegasar 500 accu is a battery powered stud welding unit for CD stud welding. Inverter-Capacitor Charging Technology: maximum welding rates, minimum energy consumption, minimum weight, maximum efficiency. Primary power: 110 V to 240V, 50/60 Hz, 10 AT, in battery (accumulator) operation: V Battery (accumulator) charging time: Max. 2.5 hours Battery (accumulator) operating time and # of welds: 400 charging cycles, 400 welds-1/4 (M6) Welding Material: Mild steel, stainless steel, aluminum Lightweight and rugged shell Simple to operate. Quick access buttons and pre-stored parameters. Fine tuning +/- buttons. Settings are auto saved. Suitable Welding Gun: C06-3 Welding Cable Length: 10 feet. Ground Cable: 8.20 ft. with vice grip. Optional: Extra battery(s) and separate charging station. A Complete System includes (one each) power unit, gun, battery and ground cable. Dimensions: x x Welding Time: 1 to 3 ms Weight: lbs. with battery lbs. without battery Stud Diameter Range: Studs (steel): #4 to 1/4, 14 ga to 1/4 ; M3 to M6, 2 to 6mm Capacitance Charge: 100,000 Capacitance: 100,000 mf Weld Rate: 12 Ga, M3= 40 studs/min 1/4, M6= 20 studs/min 3/16 (M4) Max diameter aluminum Charging Voltage: V (stepless voltage regulation) Input Power: 230/115 V, 50/60 Hz, 10 AT Cooling Type: F (temp. control cooling fan) IP Code: IP 44 PART LIST System Complete P500 accu Charger Gun (C06-3) Battery Ground Houston, Texas

17 13-17 Houston, Texas

18 PRODUCTION WELDERS FULL RANGE CAPABILITIES From the basic single-head, hand-loaded stationary bench welder, to the most sophisticated multi-head auto-feed CNC fully automated systems available anywhere; SUNBELT is the source for production stud welders. Houston, Texas

19 PRODUCTION WELDERS EXPERT ASSISTANCE Looking for a special system to help increase and/or smooth your production? Call the experts; SUNBELT s Equipment Consultants will assist you to identify, design and build the production equipment best suited to your application. Houston, Texas

20 RENTAL EQUIPMENT LARGE RENTAL FLEET D Sunbelt Stud Welding, Inc. stocks a complete line of stud welding equipment. Equipment is available to rent per day, per week, or per month. Houston, Texas

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