Image Industries CD 110 Operation Manual page 16

Section 4
Problem
Broken ground cable or incomplete
connection.
Broken weld tool, weld cable or incomplete
connection.
Broken control cable.
Welder turns on but
does not operate.
Shorted trigger switch (trigger LED always
on).
Faulty trigger switch (trigger LED doesn't
light when trigger pulled).
Faulty control board.
Shorted main charge SCR.
Weld too hot
Shorted bank charge SCR.
regardless of voltage
Faulty voltage potentiometer
setting.
Faulty control board.
Faulty control board.
Green ready LED
Disconnected LED
doesn't light.
Faulty LED
Faulty control board.
Voltage Adjust knob turned up too high.
Green ready LED
blinks, welder doesn't
operate.
Faulty voltage potentiometer.
Faulty bank select switch.
Missing or faulty ground.
Yellow contact LED
Broken sense wire (gap weld tool).
doesn't light when
Disconnect LED.
weld tool is placed
Faulty LED
against work.
Faulty control board.
Broken control cable.
Red trigger LED
Control cable not fully connected.
doesn't light.
Faulty trigger switch.
Disconnect LED.
Faulty LED
Faulty control board.
Circuit fuse or Shorted weld capacitor.
CD110 breaker blows
each time unit is
Shortened bridge rectifier.
powered on.
Incorrect primary connections.
Shortened transformer.
Possible Cause
Trouble Shooting
Corrective Action
Make sure all cable connections are in good condition and are tightly secured.
Make sure all cable connections are in good condition and are tightly secured.
Verify continuity on all leads in the control cable (black and white only for
contact weld tools).
Verify continuity on the trigger switch. Replace if defective.
Verify continuity on the trigger switch. Replace if defective.
Replace control board.
Replace charge SCR.
Replace charge SCR.
Verify voltage pot wiper has a resistance of 0-500 ohms. Replace if defective.
Replace control board.
Replace control board.
Ensure LED is seated in holder and holder is pressed firmly onto bezel.
Replace LED
Replace control board.
Turn the Voltage Adjust knob counter-clockwise. Check voltage adjust
potentiometer for correct functionality.
Verify voltage pot wiper has a resistance of 0-500 ohms. Replace if defective.
Verify switch selects one output per position. Replace if defective.
Make sure all cable connections are in good condition and are tightly secured.
Verify continuity on all leads in the control cable.
Ensure LED is seated in holder and holder is pressed firmly onto bezel.
Replace LED
Replace control board.
Verify continuity on all leads in the control cable (black and white only for
contact weld tools).
Make sure all cable connections are in good condition and are tightly secured.
Verify continuity on the trigger switch. Replace if defective.
Ensure LED is seated in holder and holder is pressed firmly onto bezel.
Replace LED
Replace control board.
Use a capacitance meter to test weld capacitor. Visually inspect weld capacitor
for obvious signs of damage. Replace defective weld capacitor.
Replace bridge rectifier.
Check the jumper links on the transformer.
Replace transformer.
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