Operation Manual - Image Industries
Contents
1. Flying metal can injure eyes Welding chipping wire brushing and grinding can cause sparks and flying metal As wow di welds cool they can throw off slag Therefore 1 Wearapproved safety glasses with side shields even under your welding helmet 2 Warn others nearby about flying metal hazard EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore Always have qualified personnel perform the installation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance work inside a power source disconnect the power source from the incoming electrical power 3 Maintain cables grounding wire connections power cord and power supply in safe working order Do not operate any equipment in faulty condition 4 Donotabuseany 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 Keepallsafety devices and cabinet covers in position and in good repair 6 Use equipment only for its intended purpose Do not modify itin any manner MOVING PARTS CAN CAUSE INJURY Electric fan can start at any time without warning and cause severe injury therefore Always disconnect electrical power prior to service to prevent the fan from starting unexpecte2. 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 PROTECT YOURSELF AND OTHERS Some welding cutting and gouging processes are noisy and require ear protection The arc like the sun emits ultraviolet UV and other radiation and can injure skin and eyes Hot metal can cause burns Training in the proper use of the processes and equipment is essential to prevent accidents Therefore Always wear safety glasses with side shields in any work area even if welding helmets face shields and goggles are also required Use a face shield fitted with the correct filter Cover sparks and rays of the arc when operating or observing operations Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric arc or hot metal Wear flameproof gauntlet type gloves heavy long sleeve shirt cuffless trousers high topped shoes and a welding helmet or cap for hair protection to protect against arc rays and hot sparks or hot metal A flameproof apron may also be desirable as protection against radiated heat and sparks Hot sparks or metal can
3. can rupture and violently release gas Sudden rupture of cylinder valve or relief device can injure or kill Therefore 1 Usethe proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder Do not use adaptors Maintain hoses and fittings in good condition 2 Always secure cylinders in an upright position by chain or strap to suitable hand trucks undercarriages benches walls post or racks Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit 3 When notin 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 4 Locate cylinders away from heat sparks and flames Never strike an arc ona cylinder 5 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 HEARING PROTECTION Prolonged Noise from Capacitor Discharge welding applications can damage hearing if levels exceed limits specified by OSHA Therefore 2 Use Approved ear plugs or ear muffs if noise level is high Warn others nearby about noise hazard For additional information refer to OSHA Safety Standards 3074 N 5 a EYE PROTECTION
4. 2 BLACK Contact LED White Contact LED Black 17V 2A 17V 2B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 4 24 Ground Ring Brown 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 ONTROL BOARD 5 4 WIRE 43 WHITE J4 2 BLACK WHITE J5 2 BLACK WIRE 5 iig i2 k WIRE 9 21 27 22 WIRE 12 12 WIRE 44 WIRE 42 WIRE 11 WIRE 7 GREEN READY YELLOW CONTACT RED TRIGGER WIRE 17 WIRE 15 WIRE 29 R5 Q3 WIRE 19 WIRE 13 J7 PLUG AC MALE D3 w BRIDGE WIRE 29 WIRE 13 WIRE 41 WIRE 42 swe N O SHUTDOWN THEMALSWITCH THEMALSWITCH 12 17755 AC e N J11 J12 J13 J14 12 Ti c2 WIRE 21 X R Q1 D1 WIRE 48 WIRE 46 Q2 WIRE 23 x WIRE 49 2 WIRE 47 D2 C4 R4 WIRE 27 WIRE 26 WELD Primary Bank Bank 1 Bank 2 a4 WEL
5. AISI 1006 to 1022 Low carbon steel AISI 1006 to 1010 stainless steel series 300 copper alloy 260 and 268 Stainless steel series 300 and 400 Low carbon steel AISI 1006 to 1010 stainless steel series 300 Aluminum alloys 1100 3000 series 5000 Aluminum alloy 1100 5086 6063 series 6061 and 6063 ETP copper lead free brass and rolled Low carbon steel AISI 1006 to 1010 stainless copper Steel series 300 copper alloys 260 and 268 Zinc alloys die cast Aluminum alloys 1100 and 5086 Except for the free machining Type 308 stainless steel Section 3 Normal 6194 Weld Quality Visual Inspection Too Hot Correct Too Cold Excessive weld flash Normal weld flash No visible weld flash and weld spatter No significant weld spatter This weld will break This weld may break This will be a good strong weld Reduce Voltage No Adjustments Required IncreaseVoltage Increase Spring Pressure Reduce Spring Pressure or Reduce Capacitance or Increase Capacitance Also could be caused by a short tip or a center punch mark CONTACT CAPACITOR DISCHARGE PROCESS The gun begins to drive the stud into the base metal Complete fusion v 2 2 9 zz 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 tip vaporizes and an arc is formed is completely discharged and the stud t
6. condition are tightly secured connection Broken gun weld cable or incomplete m gt Make sure all cable connections are in good condition and are tightly secured connection Verify continuity on all leads in the control cable black and white only for contact Broken control cable guns 2 trigger switch trigger LED always Verify continuity on the trigger switch Replace if defective Faulty trigger switch trigger LED doesn t light when trigger pulled Faulty control board Replace control board Verify continuity on the trigger switch Replace if defective 14 Section 6 Trouble Possible Cause horted main charge SCR Replace charge SCR horted bank charge SCR Replace charge SCR Welds too hot regardless of voltage setting ty voltage potentiometer Verify voltage pot wiper has a resistance of 0 500 ohms Replace if defective Faulty control board Replace control board Green ready LED doesn t connected LED Ensure LED is seated in holder and holder is pressed firmly onto bezel au au isi light Replace LED Faulty control board Replace control board au au au Voltage Adjust knob turned up too high Turn the Voltage adjust knob counter clockwise Check voltage adjust potentiometer for correct functionality Greeni ready LED blinks Faulty voltage potentiometer Verify voltage pot wiper has a resistance of 0 500 ohms Replace if defective welder does not operate doesn t light when gu
7. 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 buyer 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 Distributer 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 maintenance damage improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer Section 1 Safety
8. D 17 Parts List Green Section 9 Handle Handle Screw Cover Screws HSC19 37ZP Power Cord 501 Cord Grip 03 NUC25 50 2 Bezel O6 SCR ESR5O06SM 35 10 32 1 2 Hex Screw 28 10 Bellville Washer 19 09 Isolator Shoulder Washer WSN20 40 06X26 50 15 Fan Mounting Screw tems Not Shown 0000 00 Charge Resistor Charge Resistor Mounting Screw 22 Weld Capacitor 19 x Please visit us on the web at www imageindustries com IMAGE INDUSTRIES INC IMAGE INDUSTRIES INC 382 Balm Court Wood Dale IL 60191 USA Tel 630 766 7373 800 722 7883 Fax 630 766 2402 email techinfo 9 imageindustries com
9. Faulty power switch Replace power switch Faulty control board Replace control board Weld SCR shorted Replace weld SCR Faulty power switch immediately Faulty control board Replace control board Wieider shuts down ina Charge SCR shorted or open Replace charge SCR Faulty power switch Replace power switch few seconds Replace control board F few minutes Welder shuts down after a weld Incorrect gap gun adjustment Gap process welds must complete within 400ms of trigger pull Make adjustment per your gun s service manual Faulty control board Replace control board 15 System Maintenance SYSTEM MAINTENANCE Power Supply This system has been designed to be essentially maintenance free The only recommended maintenance is to blow out the power supply once a year Dirt grinding dust and other contaminates can accumulate over time and they deteriorate the power supply s cooling performance If the unit is located in a dirty environment the unit should be blown out more frequently Welding Tool Typically most trouble stems from the stud gun The stud gun should be serviced once every quarter Monthly service may be required if use is exceptionally heavy Please refer to the stud gun service manual for maintenance guidelines and instructions Cables Cables are also a frequent source trouble Users often drag the power supply around by the cables This can damage cables Whene
10. ILMOO4B June 2004 Price 5 50 USD 10 Manual Capacitor Discharge Stud Welding Power Source CD110 SURE THIS INFORMATION REACHES THE OPERATOR EXTRA COPIES ARE AVAILABLE THROUGH YOUR SUPPLIER THESE INSTRUCTIONS ARE FOR EXPERIENCED OPERATORS f you are not fully 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 LELIA Contents SECTION 1 Safety Precautions 3 SECTION 2 Set Up 7 SECTION 3 Normal Operation 10 SECTION 4 Trouble Shooting 14 SECTION 5 System Maintenance 16 SECTION 6 Schematic Diagram 17 SECTION 7 Part List 18 WARRANTY 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 goods at Buyer s expense after notice to Image The warranty shall be
11. attention to hazards which could CAUTION result in minor personal injury Section 2 Installation Cage LOCATION The power supply should be located e On a flat level surfaces with adaquate 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 POWER REQUIREMENTS Fusing Cable Recommendations Input Voltage Frequency Fusing 110 V 50 60Hz 15A 220 V 50 60Hz 10A WARNING WARNING Do not defeat the incoming power cable ground on the power supply Extension Cord specifications for incoming power If an extension cable is required one is not recommended 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 SETTING JUMPER LINKS This power supply ships pre wired as 110V If you plan on using 110V no changes are required The unit can be configured to operate on 220V If you would like to wire your unit to operate on 220V the jumper link arrangement and the power cord plug must be changed NOTE Charge time will not vary between 110 and 220V Always disconnect the incoming power line when working inside of electrical equipment E
12. d results Normal Operation 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 Recommended Power Supply Capacitance and Voltage Settings Contact Gun 2 tow cow co tow ve tow o T T T T T 5 46 iow v8 Low 75 iow 1 6 Med 5 mea me Hi s 58 meo 1 Low 55 Med ve Med e Med me m 99 0 meo ve tow o meo 1 6 Mea o5 v8 m 105 ma Med 18 Low 125 Med 1e Med 130 Med m4 mi 150 Hi ane Med i40 ane Med 150 ss H v4 H f _ omm mea 18 Low 1235 ve Med v4 Hi 10 5mm Hi Med Hi Med 150 Acceptable Material Combinations Typical Combinations of Base Metal and Stud Metal for Capacitor Discharge Stud Welding Low carbon steel
13. dly Keep all doors panels covers and guards closed and securely in place Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before reenergizing welder SEO ADDITIONAL SAFETY INFORMATION For more information on safe practices for electric arc welding refer to the following publications The following publications which are available form the American Welding Society 550 N W LeJuene Road Miami FL 33126 are recommended to you ANSI ASC Z49 1 Safety in Welding and Cutting AWS C5 1 Recommended Practices for Plasma Arc Welding AWS 5 6 Recommended Practices for Gas Metal Arc Welding AWS SP Safe Practices Reprint Welding Handbook ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances 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 hazards which if not avoided will result in immediate serious personal injury or loss of life Used to call attention to potential hazards which could result in personal injury or lost of life Used to call
14. effectively Use of center punch or witness marks 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 Loose collet or chuck If the inside of the collet looks like there are threads in it then the collet is worn out and should be replaced Dirt in gun preventing smooth operation ervice gun per your gun s service manual Cables are coiled ncoil weld and ground cables Voltage incorrect for size stud to be welded Studs or pins not perpendicular the If the operator can not suitably hold the welding tool perpendicular to the work work surface ired Arc blow all weld material moves or blows to one side Move ground connections away from weld zone pace ground connections evenly around weld zone Adjust plunge per gun s service manual Adjust spring pressure per the gun s service manual urn the voltage adjust knob counter clockwise to decrease weld voltage f using a gap gun decrease the weld gap per the gun s service manual Reposition ground clamp to steer weld material Weld material will flow away from the ground clamp Ground s not positioned properly Use double grounds one on each side of the weld zone to balance current flow Broken ground cable or incomplete Make sure all cable connections in good
15. en 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 wel
16. ght will go out for a moment as the proper voltage is reached This light can also flash out error codes if certain error conditions occur see troubleshooting for specific error conditions ROTARY KNOBS Voltage Control Knob The upper rotary knob controls the weld voltage Turning the knob clockwise increases the weld voltage up to about 190V turning the knob counter clockwise will decrease the weld voltage down to about 40V The power supply will take a moment to achieve the desired setting Small changes make it easier to hit a target voltage level 10 Section 3 Normal 64194 Capacitance Select Knob The lower rotary knob has 3 positions The operator can select from 3 different capacitance levels Low 66 000uF Medium 88 000uF High 110 000uF These different capacitance levels allow the power supply to be fine tuned to match the exact welding application for the highest quality most repeatable results 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 Wh
17. he gun 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 Note 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 13 Trouble Shooting TROUBLE SHOOTING This guide references components inside the welding power supply Working inside a capacitor discharge CD power supply is inherently dangerous Do not DANGER 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 Corrective Action Poor weld Weld is too hot Weld is too cold Arc blow all weld material moves or blows to one side Welder turns on but does not operate Properly prepare the weld surface Make sure it is free of contaminants such as dirt Poor surface condition and oil If there is heavy oxide rust for steel or aluminum oxide for aluminum it must first be removed Poor ground connection Make sure all cable connections are in good condition and are tightly secured Broken or loose cables Make sure all cable connections are in good condition and are tightly secured 2 Do not use centerpunch witness marks to locate CD weld studs They
18. lodge in rolled up sleeves trousers cuffs or pockets Sleeves and collars should be kept buttoned and open pockets eliminated from the front of clothing Protect other personnel from arc rays and hot sparks with suitable nonflammable partitions or curtains Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can fly far Bystanders should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat from flames and arcs can start fires Hot slag or sparks can also cause fires and explosions Therefore Remove all combustible materials well away from the work area or cover the materials with a protective nonflammable covering Combustible 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 Do not do hot work on closed containers They may explode 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 equi
19. n is placed against work Disconnected LED Ensure LED is seated in holder and holder is pressed firmly onto bezel aulty LED Replace LED Faulty bank select switch Verify switch selects one output per position Replace if defective Faulty control board Replace control board Missing or faulty ground Make sure all cable connections are in good condition and are tightly secured aulty control board Replace control board Yellow LED Broken sense wire gap gun Verify continuity on all leads in the control cable Verify continuity on all leads in the control cable black and white only for contact Broken control cable guns Control cable not fully connected Make sure all cable connections are in good condition and are tightly secured light aulty trigger switch Verify continuity on the trigger switch Replace if defective Disconnected LED Ensure LED is seated in holder and holder is pressed firmly onto bezel aulty LED Replace LED aulty control board Replace control board Use a capacitance meter to test function of each weld capacitor Visually inspect Shorted weld capacitor weld capacitors for obvious signs of damage Replace any defective weld capacitor Circuit fuse or CD110 breaker blows each time Shorted bridge rectifier Replace bridge rectifier unit is powered on Check the jumper links on the transformer Replace transformer Not plugged in Welder does not tum on Breaker blown _
20. ndard 249 1 listed on page 6 for specific grounding recommendations Do not mistake the work lead for a ground cable ELECTRIC AND MAGNETIC FIELDS Electric and magnetic fields may be dangerous Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding and cutting current creates EMF around welding cables and welding machines Therefore 1 Operators having pacemakers should consult their physician before welding may interfere with some pacemakers 2 Exposure to EMF may have other health effects which are unknown 3 Operators should use the following procedures to minimize exposure to EMF Route the electrode and work cables together Secure them with tape when possible Never coil the torch or work cable around your body Do not place your body between the torch and work cables Route cables on the same side of your body Connect the work cable to the work piece as close as possible to the area being welded Keep welding power source and cables as far away from your body as possible A B D E FUMES AND GASES Fumes and gases can cause discomfort or harm particularly in confined spaces Do not breathe fumes and gases Shielding gases can cause asphyxiation Therefore 1 Always provide adequate ventilation in the work area by natural or mechanical means Do not weld cut or gouge on materials such as galvanized steel stainless steel copper zinc lead ber
21. nector Line up the flat on the weld cable connector with the small dot on the top side of the panel receptacle typically the weld cable goes into the black or negative receptacle Push the weld cable connector straight in as far as it will go Step 1 Hand turn clockwise to be tight Step 2 See Figure 3 Ground The ground cable is connected in the same fashion as the welding tool weld cable The ground cable typically is inserted into the red or positive receptacle Control Cable There is a key in the end of the control cable connector Align the key in the cable connector 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 Cable Connections Straight Polarity In straight polarity the weld tool gun is connected to the black receptacle labeled gun this is elec trode negative The ground lead is connected to the red Key way receptacle often ground This cable arrangement is the preferred Figure 4 arrangement for welding ferrous metals with either the gap or contact processes Reverse Polarity Reverse polarity reverses the weld tool and ground connec tions The weld tool connects to the red receptacle labeled ground this is electrode posi
22. pment beyond its ratings For example overloaded welding cable can 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 ELECTRICAL SHOCK Contact with live electrical parts and ground can cause severe injury or death DO NOT use welding current in damp areas if movement is confined or if there is danger of falling 1 Be sure the power source frame chassis is connected to the ground system of the input power 2 Connect the work piece to a good electrical ground 3 Connect the work cable to the work piece A poor or missing connection can expose you or others to a fatal shock 4 Usewell maintained equipment Replace worn or damaged cables 5 Keep everything dry including clothing work area cables torch electrode holder and power source 6 Make sure that all parts of your body are insulated from work and from the ground 7 Donotstand directly on metal orthe earth while working in tight quarters or a damp area stand on dry boards or an insulating platform and wear rubber soled shoes 8 Putondry hole free gloves before turning on the power 9 RefertoANSI ASC Sta
23. tive and the ground cable connects to the black receptacle labeled gun 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 gun weld cable and the ground cable when using either the gap or contact processes Normal Operation Voltage Adjustment Knob Voltage Display IMAGE ON INDUSTRIES INC Voltage Weld Voltage Meter Capacitance Trigger Contact Ready wer Groun Gun Control ka z Amber Lights when Capacitance there is a good weld path Adjustment Knob Red Lights when gun trigger is pulled Green Lights when welder is ready to weld DISPLAY FUNCTIONS The main Weld Voltage Display shows the voltage that will be used for welding There are 3 indicator lights Trigger Red This indicator lights when the trigger is pulled This shows there is a good connection through the gun trigger switch and cables Contact Amber This indicator lights when the unit detects contact with the work This means there is a good welding path Ready Green This indicator lights when the unit is ready to weld If the operator decreases the weld voltage this li
24. ven though the power switch is off and the power cable is WARNING Always be careful when working inside a capacitor storage unit disconnected there can still be voltages inside the unit Incorrect connection of the voltage select jumpers can damage the welding power supply If you are not comfortable changing the jumper links seek help from your distributor or a trained electrician Remove the power supply lid by unscrewing eight 8 10 hex head screws 5 16 wrench or nut runner The main transformer has configurable jumper links These are located directly on the main transformer on the top side of the transformer nearest the rear of the unit There are two jumper wires connected to the transformer Installation amp Set Up For a 110V configuration the jumpers connect terminals H1 and H3 and H2 and H4 Figure 1 H4 H3 H2 H1 For 220V configuration only one jumper used between terminals 2 Figure 2 H4 H2 If connecting as a 220V unit be sure and place the extra jumper in a safe place You will need it to reconnect the unit to 110V Replace the cover and reinstall the 8 10 hex head screws WARNING DO NOT OPERATE THE POWER SUPPLY WITHOUT THE COVER SECURELY PLACE Section 2 Installation 4240 Guns There are typically two cables on your welding tool a weld cable and a control cable Dot Weld Cable The weld gun cable has a camlok style con
25. ver gun 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 BUILT IN EQUIPMENT SAFETY A fault in the welding power supply can create a potentially dangerous condtion 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 Schematic PIET Section 8 17V 1A 17V 1B 17V 17V 3B L1 Hot VSET Low m WRES WIRE 24 BLUE GUN CONNECTOR L2 Hot VSET High 120 VAC Bank Switch Pin13 Revision D WIRE 10 Breaker Trip Neutral Cap Minus Discharge Resistor Charge SCR Gate Gun Common Black Bridge Plus Coil RTN Blue Bank SCR Gate Trigger RTN White Bank2 SCR Gate R1 Weld Minus Weld SCR Gate White Bank Switch Pin3 13 wp im W1 BANK SELECT Cap Plus Bank Switch Pin 2 VSET Sig Ready LED White Heady LED Black Trigger LED White WHITE Trigger LED Black
26. yllium or cadmium unless positive mechanical ventilation is provided Do not breathe fumes from these materials 2 Do not operate near degreasing and spraying operations The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene a highly toxic gas and other irritant gasses 3 Ifyourdevelop 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 4 RefertoANSI ASC Standard 749 1 see listing on next page for specific ventilation recommendations 9 ELECTRICALLY POWERED EQUIPMENT Faulty or improperly electrified 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 perform such 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 Installequipmentin accordance with the U S National Electrical Code all local codes and the manufacture s recommendations 4 Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations 4 CYLINDER HANDLING Cylinders if mishandled
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