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ILM004D

June, 2007

Capacitor Discharge Stud Welding Power Source CD110

Price     $5.50 USD

Operation 

Manual   

These INsTRUCTIONs aRe fOR expeRIeNCed OpeRaTORs.

  If 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.

BE SURE THIS INFORMATION REACHES THE OPERATOR.  EXTRA COPIES ARE AVAILABLE THROUGH YOUR SUPPLIER.

CAUTION

Summary of Contents for CD 110

Page 1: ...e 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 unde...

Page 2: ...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 limited to replacement with like good...

Page 3: ...nce damage improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer WARNING These Safety Precautions are for your protection They summar...

Page 4: ...ctical 8 DO NOT use welding current in damp areas if movement is confined or if there is danger of falling 9 Properly install and ground this equipment according to this Owner s Manual and national st...

Page 5: ...F4 1 8 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 9 Do...

Page 6: ...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 equipm...

Page 7: ...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 P...

Page 8: ...n be configured to operate on 220V AC 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...

Page 9: ...220V configuration only one jumper is used between terminals H2 and H3 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 R...

Page 10: ...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 Cable Connections Straight Polarity In straight pola...

Page 11: ...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 clock...

Page 12: ...his 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 th...

Page 13: ...1 8 130 Med 1 4 1 8 150 Hi 5 16 Hi 3 16 140 Med Hi 3 16 150 Med 3 8 Hi 1 4 170 Hi 6mm Med 1 8 125 Low Hi 1 8 130 Med Med 1 8 90 Hi 8mm Hi 3 16 140 Med Hi 3 16 150 Med Base Weld Surface Material Accep...

Page 14: ...ositioned against work on the timing or ignition tip the gun mechanisms are compressed The Trigger is pulled the ignition tip vaporizes and an arc is formed This arc melts the bottom of the stud and t...

Page 15: ...ble on page 13 to ensure that you are using the cor rect voltage for the size stud you are trying to weld Studs or pins are not perpendicular to the work surface If the operator can not suitably hold...

Page 16: ...counter clockwise Check voltage adjust potentiometer for correct functionality Faulty voltage potentiometer Verify voltage pot wiper has a resistance of 0 500 ohms Replace if defective Faulty bank sel...

Page 17: ...fter a few seconds Charge SCR shorted or open Replace charge SCR Faulty power switch Replace power switch Faulty control board Replace control board Welder shuts down after a few minutes Charge SCR sh...

Page 18: ...efer to the stud gun service manual for maintenance guidelines and instruc tions Cables Cables are also a frequent source trouble Users often drag the power supply around by the cables This can damage...

Page 19: ...VSET Low L2 Hot VSET High 120 VAC Bank Switch Pin13 Breaker Trip Neutral Cap Minus Discharge Resistor Charge SCR Gate Gun Common Black Bridge Plus Coil RTN Blue Bank1 SCR Gate Trigger RTN White Bank2...

Page 20: ...20 Parts List Section 7 1 2 3 4 6 7 11 12 15 16 20 6 9 10 8 5 19 13 14 22 18 17 23 24 30 32 28 35 36 37 39 42 34 33 41 31 27 26 25 40 29 7 38 to 24 to 34 Red Yellow Green...

Page 21: ...tion Block PKK300 19 Negative Bus Bar 2 PKE2230 20 Charge Resistor ER50W 10A Charge Resistor Mounting Screw PPC11 37ZP 22 Weld Capacitor EC200 222KE 23 Card Guide PKK101 Item Description Part Number 2...

Page 22: ...Please visit us on the web at www imageindustries com...

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