Operation Manual - Image Industries
Contents
1. uon29uuo5 oN uMo4g 05 uns X EE ond SC D A ET DN Di ta umag t pelg gt peid Jeu un 4988 uno peig Q9 Sun eg OQ gan IMS LMS TOOL AIIM dv TOOL G1AM LOVLNOD NOO Hai ECH HU 100 Y eg NH Mr HG E ama Det NS H 0001 t 3LIHM HI OL HI dvo 1 NMO HI dvo zy t of weg l LNY4 SUM ar 100L3 NOO HI ICH BOINOD DL S DL 5 6 T 8 E 8 E L t L t 9 l 9 l ur or A a ale Wa Dz z a d D TWNIWYALSANIN OTIM eg V13 UMS l ON ON u Di w H DI NOHsShd u2Sq HA uDS q 3M uo S4OLVOVM MOS WHO OSL 3 D ou 3n000 99 NOHShd Fd Sd4OL Var MA pee oto MOS WHO OSL AR E m m mm E IVW Ov DTM a St M NOHSNd er NSL STM OD st 19 Parts List Section 8 Section 8 Parts Description Part Number PRC226 FHC16 1 SPM 17 38 38 NHC16ZP PRP101 PRM1300 SON17 38 19 PRM26 PRP102 PXC19 75TZ SHC16 75 PRC220 PRE1101 PPC25 75ZP PPC11 37ZP ER50W 150A ESD30013BR PRE2101 PRE2102 PRE2103 PRE2104 BHC19F 37 WLZ19ZP EC160 66KE CTN12 508 PKE1 CDNO4RFB PRE9000 PRM50 PR2. The weld tool cable inserts in the following way Line up the rectangular protrusion on Key the weld cable with the notch on the top side of the panel receptacle typically the weld FON cable goes into the negative receptacle Push the weld cable connector straight in as CK far as it will go Step 1 Hand turn clockwise to tighten Step 2 See Figure 3 EX A 2 Weld Ground The ground cable is connected in the same fashion as the welding tool weld cable The ground cable typically is inserted into the positive receptacle for straight polarity welding Figure 3 Control Cable There is a key in the end of the control cable connector Align the key in the cable con nector with the key way in the front panel control cable receptacle Push the cable connector into the front panel receptacle Step 1 When the two are seated turn the screw ring on the cable connector clockwise Step 2 This will lock the two together See Figure 4 The screw ring does not need to be overly tight Key TY QU Cable Connections Straight Polarity In straight polarity the weld tool weld cable is connected to the negative electrode The ground lead is connected to the positive receptacle often labeled ground This cable arrangement is the preferred arrangement for welding ferrous metals with either the gap or contact processes Figure 4 Reverse Polarity Reverse polarity revers
3. Q m Uu B Stainless Steel Stud Size Plunge Voltage Spring Stud Size Plunge Voltage Gap 12 ga Cuphead Pins 10 ga Cuphead Pins oo t Gap Weld Tool Voltage Settings N 00 Ad 3 bi Uu ES a E 9 gt K Q a c o E E o o Q x 8 x D a qd iv o oOo m Uu B Sp gd o gt o9 N 7 v 23 M 2 Stainless Steel Stud Size Voltage Gap be o 2 Voltage G DO eo ES Lo EIS oi EE ES L L zm ZZZ Fin Note Spring and Gap settings are shown for Image GA GL CA and CL weld tools 15 Trouble Shooting This guide references components inside the welding power supply Working inside a capacitor A DAN GE H 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 Possible Cause Corrective Action Error Code EO1 A ground fault has been detected Verify that the outlet and other cables are wired correctly Error Code E02 The positive side weld SCR is bad Have a qualified service tech check and replace the weld SCR Error Code E04 he positive phase high charge SCR is bad Replace contro board CAUTION Dangerous voltage may exist inside the welder Have a qualified service tech to check voltages befo
4. manufacturer or a service facility designated by the manufacturer This symbol appearing throughout this manual means ATTENTION BE ALERT Your safety is involved The following definitions apply to DANGER WARNING CAUTION found throughout this manual Used to call attention to immediate haz DANGER ards which if not avoided will result in immediate serious personal injury or loss of life Used to call attention to potential hazards WARNING which could result in personal injury or lost of life CAUTION Used to call attention to hazards which could result in minor personal injury WARNING These Safety Precautions are for your protection They summarize precautionary information from the references listed in the Additional Safety Information section Before performing any installation or operating procedures be sure to read and follow the safety precautions listed below as well as all other manuals material safety data sheets labels etc Failure to observe Safety Precautions can result in injury or death Safety Precautions ARC RAYS CAN BURN EYES AND SKIN ELECTRICAL SHOCK The arc like the sun emits ultraviolet and infrared visible and SCH Contact with live electrical parts and ground can cause severe invisible and other radiation and can injure skin and eyes injury or death The electrode the weld stud and chuck and Sparks and hot metal can fly off the weld Training in the
5. or cadmium unless positive mechanical ventilation is provided Do not breathe fumes from these materials If your develop momentary eye nose or throat irritation while operating this is an indication that ventilation is not adequate Stop work and take necessary steps to improve ventilation in the work areas Do not continue to operate if physical discomfort persists Refer to ANSI ASC Standard Z49 1 for specific ventilation recommendations CYLINDER HANDLING Shielding gas cylinders contain gas under high pressure If dam aged or mishandled a cylinder can explode and violently release gas Sudden rupture of cylinder valve or relief device can injure or kill Since gas cylinders are normally part of the welding process be sure to treat them carefully Therefore Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs Keep cylinders away from any welding or other electrical circuits Never drape a welding tool over a gas cylinder Never allow a welding electrode weld stud to touch any cylinder Use the proper gas for the process and use the proper pressure reducing regulator hoses and fittings designed to operate from the specific compressed gas cylinder Do not use adaptors Maintain hoses and fittings and other associated parts in good condition Always secure cylinders in an upright position by chain or strap to suitable hand trucks undercarriages benches walls post or rack
6. 269 9101 phone 617 770 3000 website www nfpa org and sparky org 1 NFPA Standard 70 National Electrical Code 2 NFPA Standard 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 website www cganet com 1 CGA Pamphlet P 1 Safe Handling of Compressed Gas Cylinders Canadian Standards Association Standards Sales 178 Rexdale Blvd Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 in Toronto 416 747 4044 website www csa international org 1 CSA Standard W117 2 Code for Safety in Welding and Cutting American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org 1 ANSI Standard Z87 1 Practice for Occupational and Educational Eye and Face Protection U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 phone 312 353 2220 website www osha gov 1 Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q amp Part 1926 Subpart J Occupational Safety and Health Standards for General Industry With any power source it may or may not contain a battery which may contain hazardous materials Please follow local battery disposal procedures when changing batteries or disposing of the power supply Specifications POWER REQUIREMENTS Fusing Cable Recommendations Input Voltage
7. 5 FUMES AND GASES Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health particularly in confined spaces Do not breathe fumes and gases Shielding gases can cause asphyxiation Therefore Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDS and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe Don t weld in locations near degreasing cleaning or spraying operations The heat amp rays of an arc can react with vapors to form highly toxic amp irritating gases Don t weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded Do not weld cut or gouge on materials such as galvanized steel stainless steel copper zinc lead beryllium
8. Frequency Fusing 110 V 50 60Hz 15A 220 V 50 60Hz 15A 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 10 meters use a minimum of 14 3 wire extension cable 50 ft 15 meters use a minimum of 12 3 wire extension cable WARNING WARNING Do not defeat the ground on the incoming power cable Electrical Input Voltage 100V 230V single phase Duty Cyde 24 Max Voltage Welds per minute 150V Max Voltage output 150V 110V or greater input voltage Aperage output 3 000 to 12 000 depending on settings and the type of weld tool being used Mechanical Dimensions Inches mm Height 61 8 155 Width 93 8 238 Length 71 4 184 Weight Sizes Lbs Kg Power Unit 10 5 4 76 Section 3 Installation L EAS 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
9. ILMOO7A June 2006 Price 5 50 USA epis Ty Manual Capacitor Discharge Stud Welding Power Source CD66 Oj A 2 i BE SURE THIS INFORMATION REACHES THE OPERATOR EXTRA COPIES ARE AVAILABLE THROUGH YOUR SUPPLIER THESE INSTRUCTIONS ARE FOR EXPERIENCED OPERATORS f you are not fully C A U T I O N 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 in structions If you do not fully understand these instructions contact your supplier for further in formation Be sure to read the Safety Precautions before installing or operating this equipment LEIDER Contents SECTION I Safety Precautions 3 SECTION 2 Specifications 8 SECTION 3 Set Up 9 SECTION 4 Normal Operation Ti SECTION 5 Trouble Shooting 16 SECTION 6 System Maintenance 18 SECTION 7 Schematic Diagram 19 SECTION 8 Parts List 20 WARRANT Y Image warrants that the goods sold will be free from defects in workmanship and material This warranty is expressly in lieu of other warranties expressed or implied or for fitness for a particular purpose The liability shall arise only upon return of the defective goo
10. M51 PRHOO1 PRHOO2 PRHOO3 NPC50 PRM900 PRE902 PRHOO5 PRC222 PRC218 BHC19F 37 NHC19FZP PRM500 CD66 Housing Assembly Flat Head 48 32 X 1 Stand Off Nylon Nut Hex Steel 8 32 CH e Main Control Board Face Plate Assembly Stand Off Nylon UI 166 ID 375 Switch Actuator Button User Interface PCB Pan Head 10 14 X 3 4 Mild Steel Socket Head Cap Screw 8 32 X 3 4 2 Heat Sink Mounting Block 3 Heat Sink 14 1 4 20 X 3 4 Pan Head Screw 15 Pan Head Phillips 4 40 X 3 8 6 Resistor 50W 150 OHM 17 SCR Diode Module 18 19 20 21 22 23 24 25 6 27 28 29 30 31 32 3 34 35 36 37 38 39 40 4 42 07 0 Ti Cap Plus Bus Bar Cap Neg Bus Bar Weld Ground Bus Bar Weld Negative Bus Bar Button Head 10 32 X 3 8 10 Lock Washer Weld Capacitor Cable Tie Nylon Circuit Breaker Weld Ground Cable Receptacle Power Cord Grey 8 N Strain Relief Extended Nut Strain Relief Power Harness Weld Harness Control Cable Harness Nut 1 2 NPT Fan Guard Fan Assembly Operator Interface Cable Screen Cover Filter Intake Button Head 10 32 X 3 8 Nut Hex 10 32 D Ring w Shoulder Strap partial view 21 4l Please visit us on the web at www imageindustries com IMAGE INDUSTRIES INC Imagination Working For You IMAGE INDUSTRIES INC 11220 E Main Street Huntley IL 60142 USA Tel 847 659 0100 800 722 7883 Fax 847 659 0108 www imageindustri
11. ds at Buyer s expense after notice to Image The warranty shall be limited to replacement with like goods or at Image s option to refunding the purchase price Image will not accept receipt of equipment returned unless buyer has previously afforded 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 Section 1 Safety Bd d T TERES USERS RESPONSIBILITY 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 Defective equipment should not be used Parts that are broken missing worn distorted or contaminated should be replaced immediately Should such repair or replacement become necessary the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom purchased This equipment or any of it s parts should not be altered without the prior written approval of the manufacturer The user of this equipment shall have the sole responsibility for any malfunction which results from improper use faulty main tenance damage improper repair or alteration by anyone other than the
12. e in good condition and are tightly secured doesn t light when weld tool is placed against ie ele Faulty control board Replace control board Broken control cable Verify continuity on all leads in the control cable black and white only for contact weld tools i trigger LED doesnt Control cable not fully connected Make sure all cable connections are in good condition and are tightly secured Weld too hot regardless of voltage setting Faulty trigger switch Verify continuity on the trigger switch Replace if defective Faulty control board Replace control board Breaker blows Shorted weld capacitor Use a capacitance meter to test weld capacitor Visually inspect weld capacitor for obvi each time unit is ous signs of damage Replace defective weld capacitor ep ep Welder shuts down Weld SCR shorted Check Error Code E02 and E03 take corrective action to replace weld SCR immediately Faulty power switch Replace power switch Rep he P Welder shuts down Id SCR shorted Check Error Code E02 and E03 take corrective action to replace weld SCR after a weld Incorrect gap weld tool adjustment Gap process welds must complete within 2 seconds of trigger pull Make adjustments per the weld tool s Operation Manual Faulty control board Replace control board ty control board ace control board 17 System Maintenance SYSTEM MAINTENANCE Power Supply This unit is equipped with a fres
13. e welding operation 100 meters from any sensitive electronic equipment 5 Be sure this welding machine is installed and grounded according to this manual 6 If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area HOT PARTS CAN CAUSE SEVERE BURNS 1 Do not touch hot parts with bare hands 2 Allow cooling period before working on welding tool gun or torch iliis EMF Information Considerations about welding and the effects of low frequency Electric and Magnetic Fields EMF Welding current as it flows through welding cables will cause electromagnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgement has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting See section on EMF on page 2 Section 1 Safety Bd d T TERES California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which co
14. es com email sales imageindustries com
15. es the weld tool and ground connections The weld tool weld cable connects to the positive receptacle and the ground cable connects to the negative electrode This cable arrangement is preferred for welding materials such as aluminum brass or galvanized with either the gap or contact processes Layout The cables must be laid out straight If the cables are coiled the amount of energy available for weld will be reduced This will result in poor quality welds This is true for both the weld tool weld cable and the ground cable when using either the gap or contact processes Section 4 Normal Lellig Voltage Display also messge display OA NIN 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 The display will show either GAP or CON for 2 seconds indicating the units current mode of operation There are 5 indicator lights Trigger Red This indicator lights when the trigger is pulled This shows the trigger is functioning normally L Contact Amber This indicator lights when the unit detects contact with the work This means there is a good welding path du Ready Green This indicator lights when the unit is ready to we
16. f the inside of the collet looks like there are threads in it then the collet is worn out and should be replaced Studs or pins are not perpendicular to the work surface 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 Arc Blow all weld material moves or blows to one side Space ground connections evenly around the weld zone Weld voltage too high Decrease weld voltage Move ground connections away from weld zone Weld is too hot Spring pressure too low Increase the spring pressure per weld tool s Operation Manual Weld is too cold Weld voltage too low Increase weld voltage Gap too large when using gap process If using a gap weld tool decrease the weld gap per weld tool s Operation Manual Incorrect plunge setting Adjust plunge per weld tool s service manual Incorrect spring rate Adjust spring pressure per weld tool s service manual Gap too small when using gap process If using a gap weld tool increase the weld gap per weld tool s Operation Manual Plunge too small Increase the plunge per weld tool s Operation Manual Plunge too large Decrease the plunge per weld tool s Operation Manual Spring pressure too high Decrease the spring pressure per weld tool s Operation Manual Section 5 Trouble SIT Possible Cause Corrective Actio
17. h 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 Welding Tool Typically most trouble stems from the stud weld tool The stud weld tool should be serviced once every quarter Monthly service may be required if use is exceptionally heavy Please refer to the stud weld tool service manual for maintenance guidelines and instructions Cables Cables can be a frequent source trouble Users often drag the power supply around by the cables This can damage cables Whenever the weld tool service is performed the cables should be visually inspected for worn damaged insulation or fraying wire If the cables are damaged they should be repaired to prevent any degradation of weld quality and to protect operator safety BUILT IN EQUIPMENT SAFETY A fault in the welding power supply can create a potentially dangerous condition The microprocessor continually monitors the system for faults and shuts the unit off when one is detected This is done for operator and equipment safety purposes The unit can be restarted but will shut down again as soon as the fault condition is detected The unit must be repaired Serious faults resulting from component failure disable the unit for operator safety Schematic alte Section
18. in any manner Safety Precautions MOVING PARTS CAN CAUSE INJURY e 1 Keep hands hair loose clothing and tools away from moving parts such as fans 2 Keep all doors panels covers and guards closed and securely in place 3 Always disconnect electrical power prior to service to prevent the fan from starting unexpectedly H F RADIATION CAN CAUSE INTERFERENCE 1 High Frequency H F can interfere with radio navigation safety services computers and communications equipment 2 Have only qualified persons familiar with electronic equipment perform this installation 3 The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation 4 If notified by the FCC about interference stop using the equipment at once 5 Have the installation regularly checked and maintained 6 Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING CAN CAUSE INTERFERENCE 1 Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots 2 Be sure all equipment in the welding area is electro magnetically compatible 3 To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor 4 Locat
19. 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 LOCATION If the power supply is stationary it 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 n a dry area away from moisture To protect it from grinding dust and other contaminates To provide min 6 clearance on all sides for cooling If the power supply is worn it should be located On your shoulder with strap provided Note Remove if heat should become excessive n a dry area away from moisture Do not use in the rain or while standing in a puddle Near the work area to limit welding cable length shorter lengths are preferred Avoid looping the weld cables Care should be taken to avoid a falling hazard as the ground cable and weld tool cables can catch on other objects When working off the ground a safety harness should always be used To protect it from grinding dust and other contaminates Installation amp Set Up Weld Tool There are two cables on your welding tool a weld cable and a control cable Weld Cable dinse connector
20. ist strap BEFORE handling boards or parts 2 Use proper static proof bags and boxes to store move or ship PC boards WELDING WIRE CAN CAUSE INJURY 1 Do not press weld tool trigger until instructed to do so 2 Do not point weld tool toward any part of the body other people or any metal when threading welding wire MOVING PARTS CAN CAUSE INJURY 1 Keep hands hair loose clothing and tools away from moving parts 2 Keep away from pinch points such as drive rolls EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the installation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to do the work 2 Before performing any work inside a power source disconnect the power source from the incoming electrical power using the disconnect switch at the fuse box before working on the equipment 3 Maintain cables grounding wire connections power cord and power supply in safe working order Do not operate any equipment in faulty condition 4 Do not abuse any equipment or accessories Keep equipment away from heat sources such as furnaces wet conditions such as water puddles and inclement weather oil or grease corrosive atmospheres 5 Keep all safety devices and cabinet covers in position and in good repair 6 Use equipment only for its intended purpose Do not modify it
21. ld If the operator changes the weld voltage this light will go out for a moment as the proper voltage is reached E Thermal Overload Red Turns on when the weld unit s internal temperature is outside the safe operating range e Safety Green Safety circuits within the unit are operating properly when lit Voltage Control The two rubber buttons located on the weld unit face plate controls the unit s weld voltage Pressing the right button will increase the weld voltage up to a maximum of 150V press the left button to decrease the weld voltage down to a minimum of 40V The power supply will take a moment to achieve desired setting The ready light will light green when the power source is ready to weld Press and hold either button to rapidly increase indicated value quickly press buttons for fine adjustment 11 Normal Operation 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 Provided no errors are detected the power supply will then charge to the voltage level indicated on the Main Weld Voltage Display When charging is complete 3 seconds maximum the ready light will turn on Note If the trigger is held or the weld tool is in contact with the work charging will be disabled until the
22. n Arc blow all weld ma J 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 Broken ground cable or incomplete connection Make sure all cable connections are in good condition and are tightly secured Broken weld tool weld cable or incomplete con J Make sure all cable connections are in good condition and are tightly secured Welder turns on nection but does Broken control cable Verify continuity on all leads in the control cable black and white only for contact weld not operate tools Shorted trigger switch trigger LED always on Verify continuity on the trigger switch Replace if defective Faulty trigger switch trigger LED doesn t light Verify continuity on the trigger switch Replace if defective when trigger pulled Faulty control board Replace control board Faulty control board Replace control board Faulty control board Replace control board ae ready LED Unit detects trigger Check cables Ensure trigger switch is not broken doesn t light Unit detects contact Check cables Ensure weld tool is not touching grounded work piece Green ready LED Faulty control board Replace control board blinks welder doesn t operate Yellow contact LED Missing or faulty ground Make sure all cable connections ar
23. n overheat and create a fire hazard After completing operations inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire Use fire watchers when necessary For additional information refer to NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Processes available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NOISE CAN DAMAGE HEARING Noise from some processes or equipment can damage hearing 1 Wear approved ear protection if noise level is high FIRE OR EXPLOSION HAZARD 1 Do not install or place unit on over or near combustible surfaces 2 Do not install unit near flammables 3 Do not overload electrical wiring be sure power supply system is properly sized rated and protected to handle the unit amn an 7 PN CS J ch oy ka E FALLING UNITS CAN CAUSE INJURY 1 Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories 2 Use equipment of adequate capacity to lift and support unit 3 If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of the unit OVERUSE CAN CAUSE OVERHEATING 1 Allow cooling period follow rated duty cycle 2 Reduce current or reduce duty cycle before starting to weld again 3 Do not block or filter airflow to unit STATIC ESD CAN DAMAGE PC BOARDS 1 Put on grounded wr
24. ntain chemicals known to the State of Cali fornia to cause birth defects and in some cases cancer California Health amp 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 Wash hands after handling For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ADDITIONAL SAFETY INFORMATION For more information on safe practices for electric arc welding refer to the following publications American Welding Society 550 N W LeJuene Road Miami FL 33126 phone 305 443 9353 website www aws org 1 ANSI ASC Z49 1 Safety in Welding Cutting and Allied Processes 2 AWS CH5 Recommended Practices for Stud Welding 3 AWS D1 1 Structural Welding 2 AWS C5 1 Recommended Practices for Plasma Arc Welding 3 AWS C5 6 Recommended Practices for Gas Metal Arc Welding 4 AWS SP Safe Practices Reprint Welding Handbook 5 ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers and Piping National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02
25. onductors first and sers high topped shoes and a welding helmet or cap for hair protection to then double check connections protect against arc rays and hot sparks or hot metal A flameproof apron may 5 Always verify the supply ground check and be sure that input power cord also be desirable as protection against radiated heat and sparks ground wire is properly connected to ground terminal in disconnect box or 4 Hot sparks or metal can lodge in rolled up sleeves trousers cuffs or pockets that cord plug is connected to a properly grounded receptacle outlet Sleeves and collars should be kept buttoned and open pockets eliminated 6 Refer to ANSI ASC Standard Z49 1 listed on page 6 for specific grounding from the front of clothing recommendations Do not mistake the work lead for a ground cable 6 Use goggles over safety glasses when chipping slag or grinding Chipped slag 7 Clamp work cable with good metal to metal contact spring and or magnetic may be hot and can fly far Bystanders should also wear goggles over safety clamps are not recommended to work piece as near the weld as practical glasses 8 DO NOT use welding current in damp areas if movement is confined or if there is danger of falling ELECTRIC AND MAGNETIC FIELDS 9 Properly install and ground this equipment according to this Owner s Manual Electric and Magnetic Fields may be dangerous Electric current and national state and local codes flowing through any conductor ca
26. onnect the work cable to the work piece as close as possible to the immediately bare wiring can kill Repair or replace damaged parts at once area being welded Maintain this unit according to the manual E Keep welding power source and cables as far away from your body as 7 Do not use worn damage undersized or poorly spliced cables possible 8 Do not drape cables over your body 9 If earth grounding of the work piece is required use a separate cable 20 Wear a safety harness if working above floor level FLYING METAL CAN INJURE EYES 21 Keep all panels and covers securely in place 22 Insulate work clamp when not connected to work piece to prevent contact 1 Welding chipping wire brushing and grinding can cause with any metal object sparks and flying metal As welds cool they can throw 23 Don t connect multiple electrodes or work cables to a single weld output off slag terminal 2 Wear approved safety glasses with side shields even under your welding helmet SIGNIFICANT DC VOLTAGE exists after removal of the input power on inverters Turn off inverter disconnect input power and discharge input BUILD UP OF GAS CAN INJURE OR KILL SE according to instructions in Maintenance Section before touching 1 Shut off shielding gas supply when not in use 2 Always ventilate confined spaces or use approved air supplied respirator Section 1 1 2 3 4 5 6 7 8 d 10 3 4 6
27. proper work circuit ground are electrically live whenever the output use of the processes and equipment is essential to prevent ac is on The input power circuit and the machine internal circuits cidents Therefore are also live whenever power is on Improperly installed or improperly grounded equipment is a hazard 1 Always wear safety glasses with side shields in any work area even if wearing a welding helmet face shields and goggles are also required 1 Disconnect input power before installing or servicing this equipment Lock 2 Always use a face shield fitted with the correct shade of filter to protect your out tagout input power according to OSHA 29 CFR 1910 147 see Safety face and eyes when welding or watching See ANSI Z49 1 and Z87 1 listed Standards in Safety Standards Cover sparks and rays of the arc when operating or 2 Do not touch live electrical parts Do not touch the electrode stud if you observing operations are in contact with the work ground or another electrode from a different 3 Use protective non flammable screens or barriers to protect others from machine flash and glare Warn bystanders not to watch the arc and not to expose 3 Be sure the power source frame chassis is connected to the ground system themselves to the rays of the electric arc or hot metal of the input power 3 Wear flameproof gauntlet type gloves heavy long sleeve shirt cuffless trou 4 When making input connections attach proper grounding c
28. re replacing the control board i oc SE Call for service to have a qualified service tech assess problem Properly prepare the weld surface Make sure it is free of contaminants such as dirt and Poor surface condition Poor ground connection be removed Error Code E03 The negative side weld SCR is bad Have a qualified service tech check and replace the weld SCR Error Code E05 The positive phase low charge SCR is bad Replace control board oil If there is heavy oxide rust for steel or aluminum oxide for aluminum it must first Make sure all cable connections are in good condition and tightly secured Broken or loose cables Make sure all cable connections are in good condition and tightly secured Use of center punch or witness marks Loose collet or chuck Do not use center punch witness marks to locate CD weld studs They effectively reduce the tip length degrading weld performance The collet 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 Poor Weld Dirt in weld tool preventing smooth operation Service weld tool per your weld tool s Operation Manual Cables are coiled Uncoil weld and ground cables Voltage incorrect for size stud to be welded Check the weld parameter table on page 13 to ensure that you are using the correct volt age for the size stud you are trying to weld I
29. s Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit When not in use keep cylinder valves closed Have valve protection cap in place if regulator is not connected Secure and move cylinders by using suitable hand trucks Avoid rough handling of cylinders Locate cylinders away from heat sparks and flames Never strike an arc or weld on a cylinder it will explode Turn face away from valve outlet when opening cylinder valve For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 Precautions 1 2 4 5 6 7 8 9 0 1 2 3 4 5 WELDING CAN CAUSE FIRES AND EXPLOSIONS Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot work piece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Therefore RIZ N Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all combustible materials a minimum of 35ft away from the welding arc or cover the materials
30. t weld Section 4 Normal fe fF titel CONTACT CAPACITOR DISCHARGE PROCESS The weld tool begins to drive the stud into the base metal Complete fusion y A 5 9 CD Stud is positioned against work The Trigger is pulled the ignition At the end of travel the power source on the timing or ignition tip the weld tip vaporizes and an arc is formed is completely discharged and the stud tool mechanisms are compressed This arc melts the bottom of the has formed a complete bond with the stud and top of the base metal base material GAP CAPACITOR DISCHARGE PROCESS Note For both processes the tip design dimensions are very important The ignition tip controls the arc length and weld duration If the ignition tip is too short there will not be enough weld time to ensure an adequate weld The weld tool continues to drive the stud toward the base metal Complete fusion Y Initial gap y y 77 y Stud starts in contact with The tool trigger is pulled and After the gap distance is Upon contact with the base At the end of travel the the work piece The stud is the tool s mechanisms lift achieved the weld tool metal the ignition tip power source is completely positioned over the target the weld stud off of the mechanism accelerates vaporizes and an arc is discharged and the stud work creating the ini
31. tial gap toward the weld site formed This arc melts has formed a complete bond the bottom of the stud with the base material and top of the base metal 13 Normal Operation Weld Quality Visual Inspection Too Hot Correct Too Cold Excessive weld flash Normal weld flash Excessive weld flash and weld spatter No significant weld spatter and weld spatter This weld may break This will be a good strong weld This weld may break ALL Reduce Voltage No Adjustments Required ALL Increase Voltage Contact Increase Spring Pressure Contact Reduce Spring Pressure Gap Increase initial gap Gap Reduce initial gap ACCEPTABLE WELDING MATERIAL COMBINATIONS Base Weld Surface Material Acceptable Stud Material LOW CARBON STEEL LOW CARBON STEEL AISI 1006 to 1010 AISI 1006 to 1022 STAINLESS STEEL 300 series except 303 COPPER ALLOY brass 260 and 268 STAINLESS STEEL LOW CARBON STEEL AISI 1006 to 1010 300 and 400 series except 303 STAINLESS STEEL 300 series except 303 ALUMINUM ALLOYS ALUMINUM ALLOYS 1100 5086 6063 1100 3000 series 5000 series 6061 and 6063 ETP COPPER LEAD FREE BRASS LOW CARBON STEEL AISI 1006 to 1010 and ROLLED COPPER STAINLESS STEEL 300 series except 303 COPPER ALLOY brass 260 and 268 Normal Lellig Section 4 RECOMMENDED POWER SUPPLY Contact Weld Tool Voltage Settings ings 4 o Uu 9 oo d o gt K d Kl c a E E o o Q a 8 E D ad U Q Ad t o H o
32. trigger is released and the weld tool is not in contact with the work Note A ground fault detection circuit is built into the unit If a ground fault is detected the unit will shut off and display error E01 Ground Fault detection is used for Operator Safety WARN N e WARNING Before applying power up to the unit make sure all cables are properly connected Note A proper earth ground connection is essential for the safe operation of this unit If earth ground is not detected the power source will display Need Earth Ground and the unit cannot be turned on Stud Weld Tool Settings Refer to the Weld Tool Manual Welding Sequence Load a weld stud into the properly sized collet Position the weld tool against the work Press down on the weld tool to make sure the template nozzle or tripod legs sit firmly against the work While holding the tool in position pull the trigger The weld will initiate and complete There is a loud pop 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 pull the weld tool off the stud When removing the tool pull the tool straight off the weld stud to prevent damage to the collet Once the weld tool is pulled off the work and the trigger is released the unit will fully charge up to the set point and be ready for the nex
33. uses localized Electric and 0 Connect the work cable to the work piece A poor or missing connection can Magnetic Fields EMF Welding and cutting current creates EMF expose you or others to a fatal shock around welding cables and welding machines 1 Keep everything dry including clothing work area cables torch electrode Therefore holder and power source 2 Wear dry hole free insulated gloves amp body protection before turning on 1 Welders having pacemakers should consult their physician before welding power EMF may interfere with some pacemakers 3 Insulate yourself from work and ground using dry insulating mats or covers big 2 Exposure to EMF may have other health effects which are unknown enough to prevent any physical contact with the work or ground 3 Welders should use the following procedures to minimize exposure to EMF 4 Don t stand directly on metal or the earth while working in tight quarters or a A Route the electrode and work cables together Secure them with tape damp area stand on dry boards or an insulating platform and wear rubber when possible soled shoes B Never coil the torch or work cable around your body 5 Turn off all equipment when not in use C Do not place your body between the torch and work cables Route 6 Use well maintained equipment Frequently inspect input power cord and out cables on the same side of your body put weld cables for damage or bare wiring Replace worn or damaged cables D C
34. with a protective nonflammable covering Com bustible materials include wood cloth sawdust liquid and gas fuels solvents paints and coatings paper etc Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below Make certain that such openings are protected from hot sparks and metal Do not weld cut or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce flammable or toxic vapors Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and caus ing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove electrode weld stud from the stud weld tool when not in use Remove any combustibles such as a butane lighter or matches from your person before doing any welding Have appropriate fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained for proper use Do not use equipment beyond its ratings For example overloaded welding cable ca
Download Pdf Manuals
Related Search