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Image CD66 Operation Manual
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Image CD66 Operation Manual

Image CD66 Operation Manual

Capacitor discharge stud welding power source
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ILM007D
July, 2008
Price
$5.50 USA
Operation
Manual
Capacitor Discharge Stud Welding Power Source CD66
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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Summary of Contents for Image CD66

  • Page 1 Price $5.50 USA Operation Manual Capacitor Discharge Stud Welding Power Source CD66 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”...

  • Page 2: Table Of Contents

    Image’s personnel a reasonable opportunity to inspect and repair said equipment. Image will warrant components for 1 year and labor for 180 days from date of shipment. Image shall not be liable for any consequential damages including improper set up by customer.
  • Page 3 Safety Precautions Section 1 U S E R S RES PONSIBIL ITY 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.

  • 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: Specifications

    Specifications Section 2 POWER REQUIREMENTS Fusing / Cable Recommendations Input Voltage Frequency Fusing 120V 50/60Hz 240V 50/60Hz Extension Cord specifications for incoming power: If an extension cable is required use the following guidelines Up to 25 ft. (8 meters) use a minimum of 16-3 wire extension cable 30 ft.

  • Page 9: Set Up

    Installation & Set Up Section 3 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.
  • Page 10 Installation & Set Up Section 3 Weld Tool There are two cables on your welding tool: a weld cable and a control cable. Weld Cable (Dinse connector) The weld tool cable inserts in the following way: line up the rectangular protrusion on Key way the weld cable with the notch on the top side of the panel receptacle (typically the weld cable goes into the negative (-) receptacle).

  • Page 11: Normal Operation

    Normal Operation Section 4 Voltage Display (also message display) Voltage Down Voltage Up DISPLAY FUNCTIONS The main Weld Voltage Display shows the voltage that will be used for welding. In addition the Weld Voltage Display will display faults present within the unit (see section 5 for additional details). The unit detects where a gap mode or contact mode weld tool is connected.
  • Page 12 Normal Operation Section 4 POWER UP When the unit is plugged in, it performs a self check, after about 2 seconds the Safety light will be lit. This means the unit is functioning properly. Even if the unit is not switched on, when operating properly, the Safety light will be lit. Press the power switch to its on position (1).
  • Page 13 Normal Operation Section 4 CONTACT CAPACITOR DISCHARGE PROCESS The weld tool begins to drive the stud into the base metal. Complete fusion The Trigger is pulled, the ignition CD Stud is positioned against work At the end of travel, the power source tip vaporizes and an arc is formed.
  • Page 14 Normal Operation Section 4 Weld Quality Visual Inspection Too Hot Correct Too Cold Excessive weld flash Normal weld flash. Little weld flash. and weld spatter. No significant weld spatter. This weld may break. This weld may break. This will be a good, strong weld. Weld Examples and Solutions ALL: Reduce Voltage ALL: Increase Voltage...
  • Page 15 Aluminum Stud Size Voltage Gap Stud Size Voltage Gap Stud Size Voltage 12 ga 12 ga 12 ga 10 ga 10 ga 10 ga Note: Spring and Gap settings are shown for Image GA, GL, CA, and CL weld tools.

  • Page 16: Trouble Shooting

    Trouble Shooting Section 5 This guide references components inside the welding power supply. Working inside a capacitor DANGER discharge (CD) power supply is inherently dangerous. Do not attempt to service components inside a CD power supply unless you have been trained in the proper safety and service procedures. If you have questions, consult your distributor or the factory directly.
  • Page 17 Trouble Shooting Section 5 Possible Cause Corrective Action Problem Arc blow (all weld ma- Ground(s) not positioned properly. Reposition ground clamp to “steer” weld material. Weld material will flow away from terial moves or “blows” the ground clamp. to one side). Use double grounds, one on each side of the weld zone to balance current flow.

  • Page 18: System Maintenance

    System Maintenance Section 6 SYSTEM MAINTENANCE Power Supply This unit is equipped with a fresh air intake filter. This filter should be replaced on a semi-annual basis. If the environment is particularly dirty, the filter should be replaced more frequently. On an annual basis, the unit should be opened up and thoroughly blown out so it is free of all contaminants.

  • Page 19: Schematic Diagram

    Schematic Diagram Section 7...

  • Page 20: Parts List

    Parts List Section 8...
  • Page 21 Parts List Section 8 120 VAC 240 VAC Item Description Part Number Part Number CD66 Housing Assembly PRC226 10143 Flat Head #8-32 X 1 FXC16-1ZP FXC16-1ZP Stand Off Nylon SON17-38-38 SON17-38-38 Nut, Hex Steel #8-32 NHC16ZP NHC16ZP Main Control Board...
  • Page 22 Please visit us on the web at www.imageindustries.com...