Normal Operation - Image Industries CD 110 Operation Manual

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.
On power up the power supply initiates a self test. This test lasts approximately 2 seconds. The power supply will then
charge the level of capacitance set by the capacitance select knob to the voltage level set by the voltage select knob. When
charging is complete (3 seconds maximum) the ready light will turn on. Note: If the trigger is held or the weld gun is in
contact with the work, charging will be disabled until the trigger is released and/or the weld gun is not in contact with the
work.
WELDING
Stud Gun Settings
Refer to Stud Gun Manual
Welding Sequence
Position the gun against the work. Press down on the stud gun to make sure the spark shield or tripod legs sits firmly against
the work. While holding the gun in position, pull the trigger. The weld will initiate and complete. There is a loud bang
(hearing protection is recommended) associated with the weld process. This completes a weld sequence. Note: Contact
must be made BEFORE the trigger is pressed, otherwise welding will not occur.
Post Weld Sequence
After the weld is complete, but before the gun is pulled off the work, the unit will charge up to about 20V. When the gun
is pulled off the work (and the trigger is released) it will fully charge to the set point. If the operator pulls the gun off the
work immediately (and releases the trigger) the unit will charge to the set point. Pull the gun off of the stud.
SET UP
Base Metal Preparation
As with most welding, clean weld studs and clean base metal will provide the best results. Typical weld penetration is .002
to .004 inches (.05 to .1 mm). Mill scale may easily be this thick. When welding to steel with mill scale, the scale must be
removed first to achieve quality weld results.
A common CD welding mistake is to use a centerpunch mark for location. The ignition tip locates nicely in the centerpunch
mark, but it effectively shortens the tip length. Since the tip is sitting in a depression, the distance from the workpiece to the
face of the weld stud is shorter. Usually, this results in bad welds.
Aluminum can quickly form a layer of oxide. Oxide is non-conductive (not good for welding) and is tough. If welding onto
aluminum is causing problems, it is often best to remove the oxide layer. This can be accomplished via abrasives. A stainless
steel brush works well.
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