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ILM004D
June, 2007
Price
$5.50 USD
Operation
Manual
Capacitor Discharge Stud Welding Power Source CD110
BE SURE THIS INFORMATION REACHES THE OPERATOR. EXTRA COPIES ARE AVAILABLE THROUGH YOUR SUPPLIER.
These INsTRUCTIONs aRe fOR expeRIeNCed OpeRaTORs. If you are not fully
CA UTION
familiar with the principles of operation and safe practices for arc welding equipment, we urge
you to read AWS SP - "Safe Practices" available from the American Welding Society.
DO NOT permit untrained persons to install, operate, or maintain this equipment. DO NOT
attempt to install or operate this equipment until you have read and fully understand these
instructions. If you do not fully understand these instructions, contact your supplier for further
information. Be sure to read the Safety Precautions before installing or operating this equipment.
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Related Manuals for Image Industries CD 110
Summary of Contents for Image Industries CD 110
- Page 1 ILM004D June, 2007 Price $5.50 USD Operation Manual Capacitor Discharge Stud Welding Power Source CD110 BE SURE THIS INFORMATION REACHES THE OPERATOR. EXTRA COPIES ARE AVAILABLE THROUGH YOUR SUPPLIER. These INsTRUCTIONs aRe fOR expeRIeNCed OpeRaTORs. If you are not fully CA UTION familiar with the principles of operation and safe practices for arc welding equipment, we urge you to read AWS SP - “Safe Practices”...
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Page 2: Table Of Contents
T a b l e o f Contents SECTION 1: Safety Precautions SECTION 2: Set Up SECTION 3: Normal Operation SECTION 4: Trouble Shooting SECTION 5: System Maintenance SECTION 6: Schematic Diagram SECTION 7: Parts List W A R R A N T Y Image warrants that the goods sold will be free from defects in workmanship and material. - Page 3 Safety Precautions Section 1 U SE R S RES PONS IBILITY This equipment will perform in conformity with the description contained in this manual and accompanying labels and/or inserts when installed, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically.
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Page 4: Safety Precautions
Safety Precautions Section 1 ARC RAYS CAN BURN EYES AND SKIN - ELEC TR I CAL SHOC K - The arc, like the sun, emits ultraviolet and infrared (visible and Contact with live electrical parts and ground can cause severe in-visible) and other radiation and can injure skin and eyes. - Page 5 Safety Precautions Section 1 FUM E S A N D GA S E S - WELDING CAN CAUSE FIRES AND EXPLOSIONS - Welding produces fumes and gases. Breathing these fumes and Welding on closed containers, such as tanks, drums or pipes, can cause them to blow up.
- Page 6 Safety Precautions Section 1 FALLING UNITS CAN CAUSE INJURY - MOVING PARTS CAN CAUSE INJURY - 1) Use lifting eye to lift unit only, NOT running gear, gas 1) Keep hands, hair loose clothing and tools away from moving cylinders or any other accessories. parts such as fans.
- Page 7 Safety Precautions Section 1 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of Cali- fornia to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
- Page 8 Installation & Set Up Section 2 LOCATION The power supply should be located: • On a flat, level surfaces with adequate air circulation • Near the work area to limit welding cable length (shorter lengths are preferred). Avoid looping the weld cables •...
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Page 9: Set Up
Installation & Set Up Section 2 For a 110V configuration the jumpers connect terminals H1 and H3 and H2 and H4. Figure 1 110 V 110 V H4 H3 H2 H1 For a 220V configuration only one jumper is used between terminals H2 and H3. Figure 2 220 V H4 H3 H2 H1... - Page 10 Installation & Set Up Section 2 Guns There are typically two cables on your welding tool: a weld cable and a control cable. Weld Cable The weld (gun) cable has a camlok style connector. Line up the flat on the weld cable connector with the small dot on the top side of the Flat panel receptacle (typically the weld cable goes into the black or negative receptacle).
- Page 11 Normal Operation Section 3 Voltage Voltage Display Adjustment Knob (Amber) Lights when Capacitance there is a good weld path Adjustment Knob (Red) Lights when gun (Green) Lights when welder trigger is pulled is ready to weld DISPLAY FUNCTIONS The main Weld Voltage Display shows the voltage that will be used for welding. There are 3 indicator lights.
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Page 12: Normal Operation
Normal Operation Section 3 POWER UP Before power up, make sure all cables are properly connected. It is also a good practice to turn the voltage control knob to the minimum voltage (all the way counter clockwise). Press the power switch (to the right or towards the 1), located on the lower left side of the control panel. - Page 13 Normal Operation Section 3 Recommended Power Supply Capacitance and Voltage Settings Contact Weld Tool Recommended Voltage Settings Mild Steel Stainless Steel Aluminum Stud Size Capacitance Plunge Voltage Spring Capacitance Plunge Voltage Spring Capacitance Plunge Voltage Spring 12 ga 10 ga 5/16 3/16 3/16...
- Page 14 Normal Operation Section 3 WELD QUALITY Visual Inspection Too Hot Correct Too Cold Excessive weld flash Normal weld flash. No visible weld flash. and weld spatter. No significant weld spatter. This weld will break. This weld may break. This will be a good, strong weld. Reduce Voltage, No Adjustments Required IncreaseVoltage,...
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Page 15: Trouble Shooting
Trouble Shooting Section 4 TROUBLE SHOOTING This guide references components inside the welding power supply. Working inside a capacitor discharge (CD) power supply is inherently dangerous. Do not attempt DANGER to service components inside a CD power supply unless you have not been trained in the proper safety and service procedures. - Page 16 Trouble Shooting Section 4 Possible Cause Corrective Action Problem Broken ground cable or incomplete Make sure all cable connections are in good condition and are tightly secured. connection. Broken weld tool, weld cable or incomplete Make sure all cable connections are in good condition and are tightly secured. connection.
- Page 17 Trouble Shooting Section 4 Possible Cause Corrective Action Problem Not plugged in. Plug in unit. Panel breaker blown. Reset breaker. Welder doesn’t turn on. Faulty power switch. Replace power switch. Faulty control board. Replace control board. Weld SCR shorted. Check Error Code (E02 + and E03 -) take corrective action to replace weld SCR.
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Page 18: System Maintenance
System Maintenance Section 5 SYSTEM MAINTENANCE Power Supply This system has been designed to be essentially maintenance free. The only recommended maintenance is to blow out the power supply once a year. Dirt, grinding dust and other contami- nates can accumulate over time and they deteriorate the power supply’s cooling performance. If the unit is located in a dirty environment the unit should be blown out more frequently. -
Page 19: Schematic Diagram
Schematic Diagram Section 6 WIRE-13 WIRE-19 WIRE-17 WIRE-29 WIRE-15 WIRE-13 WIRE-21 WIRE-46 WIRE-48 WIRE-23 WIRE-47 WIRE-49 WIRE-27 WIRE-26... -
Page 20: Parts List
Parts List Section 7 to #24 to #34 Yellow Green... - Page 21 Parts List Section 7 Item Description Part Number Item Description Part Number Handle PKM111 Positive Jumper CW2SR-.65 Handle Screw PPC31-62ZP Coupling Nut NCC19-75ZP Sheet Metal Cover PKS240-1 Connector Stud TRC19-5 Cover Screws HSC19-37ZP Fan Guard PKM900 Transformer PKE501 Knob PAM110 Transformer Mounting Nut NUC25-50 Face Plate Decal...
- Page 22 Please visit us on the web at www.imageindustries.com...