Trouble Shooting - Image Industries CD 110 Operation Manual

Section 4

TROUBLE SHOOTING

DANGER
Problem
Poor surface condition.
Poor ground connection.
Broken or loose cables.
Use of center punch or witness marks.
Loose collet or chuck.
Poor Weld
Dirt in weld tool preventing smooth
operation.
Cables are coiled.
Voltage incorrect for size stud to be welded.
Studs or pins are not perpendicular to the
work surface.
Arc Blow (all weld material moves or
"blows" to one side).
Incorrect plunge setting.
Incorrect spring rate.
Weld voltage too high.
Capacitance set too high.
Weld is too hot.
Gap too small when using gap process.
Plunge too small.
Spring pressure too low.
Weld is too cold. Weld voltage too low.
Capacitance set too low.
Gap too large when using gap process.
Plunge too large.
Spring pressure too high.
Arc blow (all weld Ground(s) not positioned properly.
material moves or
"blows" to one side).
This guide references components inside the welding power supply. Working inside
a capacitor discharge (CD) power supply is inherently dangerous. Do not attempt
to service components inside a CD power supply unless you have not been trained in
the proper safety and service procedures. If you have questions, please consult your
distributor or the factory directly.
Possible Cause
Trouble
Corrective Action
Properly prepare the weld surface. Make sure it is free of contaminants such as
dirt and oil. If there is heavy oxide (rust for steel or aluminum oxide for
aluminum) it must first be removed.
Make sure all cable connections are in good condition and tightly secured.
Make sure all cable connections are in good condition and tightly secured.
Do not use center punch/witness marks to locate CD weld studs. They
effectively reduce the tip length degrading weld performance.
The chuck should have a firm hold on the weld stud. If you are able to easily
(with no real resistance) pull the stud out of the collet then the collet is worn.
Replace collet/chuck.
If the inside of the collet looks like there are threads in it then the collet is worn
out and should be replaced.
Service weld tool per your weld tool's Operation Manual.
Uncoil weld and ground cables.
Check the weld parameter table on page 13 to ensure that you are using the cor-
rect voltage for the size stud you are trying to weld.
If the operator can not suitably hold the welding tool perpendicular to the work
surface, then a template or fixture may be required.
Use double grounds, one on each side of the weld zone to balance current flow.
Move ground connections away from weld zone.
Space ground connections evenly around the weld zone.
Adjust plunge per weld tool's service manual.
Adjust spring pressure per weld tool's service manual.
Decrease weld voltage.
Turn the capacitance knob counter-clockwise to charge fewer banks.
If using a gap weld tool, increase the weld gap per weld tool's Operation Manual.
Increase the plunge per weld tool's Operation Manual.
Increase the spring pressure per weld tool's Operation Manual.
Increase weld voltage.
Turn the capacitance knob clockwise to charge more banks.
If using a gap weld tool, decrease the weld gap per weld tool's Operation Manual.
Decrease the plunge per weld tool's Operation Manual.
Decrease the spring pressure per weld tool's Operation Manual.
Reposition ground clamp to "steer" weld material. Weld material will flow away
from the ground clamp.
Use double grounds, one on each side of the weld zone to balance current flow.
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Shooting