WIA Weldmatic 180S Owner's manual

MANUFACTURED

BY

WELDING INDUSTRIES

OF

AUSTRALIA PTY LTD

HEAD OFFICE AND EXPORT DIVISION

2-20

Austarc Auenue5

ThorrIac.town,

ERUI PMEbIT MANUFACTURING DIU1

SION

1

2

C)~OJS.

Rclad

,

Edwards

t

own

,

SCIIJ

t

h

SALES RRANC:HES

Meltuurne

83

429

4766 AA32493

Sydney

Er2

647

2655

AA24155

Newca5.t

1

e

Er49

61

1668

Bric.bane

87

844

1371

WC11

1

ongung

G142

25'

3447

Vice

3874

ph

83

465

Facsimile

G13

465

Mackay

679

51

Adel

aide

88

352

Pert

h

09

361

Launceston

863

44

251

1

AA32493

861

2

3532

3622

AA82856

7088

AA72936

53822

MELDPIAT

I

C

180

S.

PLEASE Et4SURE THAT THIS FOLDER

I

S

KEPT

IN

A

SAFE

PLACE

FOR

REAlD'Y

REFERENCE WHEN REQUI RED.

CONTENT8

SECT1

ON

1

2

3

4

6

7

8

9

c

J

F1 GUHE

1

2

3

4

5

7

E

P

18

11

d

PAGE

l

1

2

6

8

9

18

12

15

PAGE

CONTENTS

SFEC

I

F

I

CAT

I

ON$

RECE

IO1

NG

I

NSTALLAT

I

ON

CONTROLS

WELDING SET-UP

GENERAL MAINTENANCE

TROUBLE SHClOTING

CONTROL PRINTED CIRCUIT

BOARDS

SFARE PARTS LISTS

. .

,

,..

.

..

A'

WELDMATIC

188s

MANUAL

PAGE

1

L

SPEC1

F1

CAT1

ONS

1.1

TECHNI

CkL

-

Welding Output

48

-

1

88

~ITI~

C.

-

Output

us1

tagE.

21

-

38

VDC

-

Duty

Cycle.

1

E;@

ArrIF'E.,

58%

188

Amps,

35X

-

Over

1

clad

Prcttec

t

i

or1

Recti

f

i

er

Therrrlcts.tats (Thermal

j

-

Wire Speed Range

G1

-

16

metrew'mi n

-

I

n5.u

1

at

i

or1

C:~~E.C.

'H''

-

148

C;

rise

at

48

C

amtlient

-

Encl

osure

Dr

i

p-proo-f

-

1.2

STANDARD

PACKAGE

-

AM132-8/'? Nine

Metre

Accec.c.ory

Lead

Kit

-

AM132-0/15

Fifteen

Metre

Accessory

Lead

Ki

t

-

2.

RECEIVING

In genera.1

it

is

a

good practice

to

mc~ue

the equipmerlt

to

the site

of installation

before

unpackinq

Use

care

in order

to

avoid damage

t

cl

the

i

t

ems

en

c

1

osed.

If

any

damage haE. clccurred in

transit irrlrrlediatelr nutif).

We1 ding

Industries

cl+

Austral

ia

or

their authoriE.ed agent.

WELDMATIC

180s

MANUAL

PAGE

2

3.

I

NSTALLAT

I

ON

3.1

MACHINE LOCATION

Where

poc,c.ittle,

in

chctclsirrg

a

site for any welding

pOWer-50UrCe,

consideration should

be

given

tu

the

fcll lowing points:-

-

Availahility

of

electrical and c.hielding

gas

c.upp1iec..

-

Accessibility for

the

replacement

of

consumables, i.e. welding

wire and

gas

bottles, and

for

any

future rrlainterlarlce requirements.

-

The

power-source

must

be

posi

ticsned

so

that

the

free f

1

ow

of

cclcll inq air through

the

machine is

not

impeded.

-

Prcltection from wind and driven

rain

-

Breezes

bluwing through

an

open doorway can rec.ul

t

in

degradation of

the

weld c.hie1dinq

gas

coverage, which

ca.n

cause weld porosity.

If

such

a

site

is

unauoidat~le, consideration should

tle

given tcl

the

use

of portat~le

weldir~g screens of

a

suitable material.

The

nut+low

of

cooling

air

from

the

we1

ding power-~.c~urce can

a1

5.0

cause simi

lar

prcatl1

ems.,

and

the

machine should

tle

pc1s.i

tioned with

this

in

mind.

-

Airhorne dust particles 1~1i1l

always

accumulate in uented

equipment,

particularly

that

with forced air cool ing and excessive

tluildup can often

tle

the

cause

of

premature

machine failure.

Ai:

a1

1

times endeavour

to

position

the

machine to minimise

the

inta.ke

cl+

contaminated

air,

particularly

that

contairrirlq

metal

1

ic

particles such

as

from

grinding operations.

i

see

a1

5.0

MA1NTENANC:E SECT

I

ON

of

t

h

i

c.

Manual

,

plage

}

-

3.2

SUITABLE

MAINS

VOLTAGES

The

WELDtIATIC:

1861s.

is designed

for

connectic~n tu

a

s.ingle

phase!

58

hertz

electrical mainc.

power

suppl>’.

‘

L

WELDMATIC

188s

MANUAL

PAGE

3

3.3

CONNECTION

TA

ELECTRICAL

MAINS

POWER

SUPPLY

The

recommended Supply Fuse Rating

is

28

Amps.

When

making

corrnec tion

to

the

t4achine Supply terminal

s,

ensure

that

local codes

are

adhered

to,

and

that

the

EARTH

connection

is

seCurE.1

y

made.

The

bins.

Power Supply Cab1

e

c-.hould

only

be

replaced

W1

th

an

equivalent

size

cattle

as

that

fitted.

Tighten

the

two

s.crews

of

the

internal cable clamp 1es.ving

sufficient '5.1ack' in

the

Supply

Flexible

Cat11e

C.UC~

that

the

terminated

wirec.

are

not

in tension.

U

L

F1

GURE

1.

CONNECT1

ON

SUPPLY

FLEX1

BLE

CABLE

WELDMATIC:

186s

MANUAL

PAGE

4

””

3.4

CABLE

AND

HOSE

CONNECTIONS

AI

1

welding current

I

control and shielding

ac.

connectionc.

are

c.hown

in

figure

3.

The

complete

set

of necessary cablez. and

hoses

are

contained in

the

r.tar1dar.d

accec-.sory

kit

AP1132.

-SHIELDING

GAS

HOSES.

The

accessory

ki

t

CctntainC-. two

gas.

hoses.

T

h

E

4-1

or

t

er

1

en

y

t

h

i

E.

used

to

join

the

ouput

of

the

shielding

gas

regulatclr.

-

flowmeter

to

the

gas

nipple

on

the

rear

panel

cl+

the

Power-~.c~urce.

The

c.ec

und

hose

is.

used

to

make

the

gas

connection

from

the

~CIOJ~~

source front

panel

to

the

rear

of

the

L521

wirefeeder.

-CONTROL

CABLE,

Engage

the

’Wirefeeder” contrcll

catlle plug into

the

marked

socket

on

the

power source front

panel

The

con

trcll

cab1

e

connectiuns

for

the

wirefeeder

are

c.huwn

the

adjacent diagram,

-I.IELD

I

NG

CURRENT

CABLES.

G.t.1.k.

we1

ding

is

conducted with

the

el

ec trclde

polari

ty

pc1c.i

tive,

and

the

workp

i

ece

neqat

i

ve.

The

posi

tive ou

tpu

t

of

the

power

sc~urce

is.

connected to

the

welding

gun

via

an

adaptctr mounted

with

the

mire

drive rnechanic,m.

Ensure

that

the

positive

eldin ding

cat11

e

iz,

E.ecure1

y

bo1 ted

ta

thi

5

adaptor.

The

negatiue output of

the

power source is connected

to

the

welding

catlle incclrporating

the

work

clamp. Bckth leads.

c.ecured

a.t

the

puwer

source

by

inserting

the

plug into it5 appropriate socket.

WELDMATIC

188s

MANUAL

PAGE

5

WELDMATIC

180s

l

J

CONTROL

CONNECTIONS

W21-2WlRE

FEEDER

I

"

""

I

CP1

POWER

SOU=

_.

-

BIMK

OR

WHITE

BADWN

bR

RfD

CONTROL

F1

GURE

2.

CABLE

AND

HOSE

CONNECT1

ONS

L

I

WELDMATIC

188s

MANUAL

PAGE

6

QFF

0

ON

dig

E

tN/t

H

0

SPnr

TtME

WELDMATI

C

188s

MANUAL

PAGE

7

-INCH/PURGE

SWITCH:

This

is.

a

dual +unction switch.

Moving the inch/purye switch

up

initiateE. the wire

feed

mcltor,

feeding the wire into the gun cable 5ystem.

The

wire feed

speed

during inch

is

determined

tly

the settiny

cl+

the ’IJire-c,peed”

contra1

.

-L‘OtTACiE

,SW

ITCH

:

Output

v01

tage

wil

1

increase with increasing position

numbers.

-W

I

HE

SPEED

C:CNTHOL

:

-SPOT

TI

ME

CONTROL

:

-I

NTERVAL

CONTROL

:

WELDMATIC

180s

MANUAL PAGE

8

-

5.

MELDING

SET-UP

5.1

ELECTRODE W1 RE/SHI ELDING

-

Se1

ec

t

the

desired consumabl

e

el

ectrode

wire and

f

i

t

to

the

wirefeeder.

Ensure

that

the

wirefeeder ic. fitted with

the

cctrrect

drive

rollers

-

5ee

page

23.

-

Conrrect to

the

gac. regulator/fl owmeter,

a

supply

of c.hielding

yas

appropriate

to

the

welding consumable.

MI

L6,

STEEL

STAINLESS STEEL

SI

L1

CON

BRONZE

TYFICAL SHIELDING

GAS

ARGON

or

ARGON

/'

HEL

I

UP1 P1

I

XTURES

-

Set the gas floo~ rate

to

suit

the

welding procedure,

usually

in

the

range

of

18

to

15

1

itres./min.

NOTE:- Excessive

gas flow

is

coc.tly and

may

adversely affect

the

we1

ding

resul

t.

r

WELDING

CURRENT(Arnps)

30440~

50,604

70,85,100,120#140#t60,iB

WIRE SPEED

DIAL

SETTING

1-4 2.0

2.8

3.6

4.0

7.0

6mm

VOLTS

135558

DIAL

SETTING

WIRE

SPEED

1

1.3

1.6

1.9

2.2

3.3

4.8

6.8

8mm

VOLTS

l23346810

I

WIRE SPEED

DIAL SETTING

.7

.8

1 1.2

1.8

2.2 3

3.8

6

9mm

VOLTS

I

l234457810

WlRE SPEED

DIAL SETTING

1 1.2

1.5

1.8

2.5

1.2mm

VOLTS

I

56789

SETTINGS GIVEN

FOR

C02 SHIELDING GAS.-FLOW RATE 8-1OLITRES/MINlJTE.

USE

THIS CHART AS A PRELIMINARY SETTING GUIDE. TO'TUNE'EACH WELD

SETTING,

ADJUST

WIRE

SPEED

ONLY

F1

GURE

4.

WELD SETTING CHART

WELDMATIC

18Bs

MANUAL

PAGE

10

”

7.1

POOR

WELDING

RESULT

-

Check

for gclud wire feed conditions,

i

.e.

spr~ol

holder

brake

not

ouer-tightened, drive

rollers

not clcqged

with

dust build-up, driue

rcll

lers

are

the

correct

size

and

type

to

suit

the

welding wire5 and

the

driue roll

pressure

is

adequate for consistent .feeding.

Chec

k

&l

5.0

that

the

gun cab1

e

1

iner

i

5.

of ccfrrec

t

r.ire

and not bl clcked and

that

the

welding

tip

is

in

good condition and nut excessively

worn.

A1

1

of

the

ahue

can cause erratic

el

ding

cclrrdi

t

ions and

IT

IS

THE

AREA

WHICH

HAS

THE

HIGHEST

PROBABILITY

OF

FAILURE

IN

ALL

GAS

METAL

ARC

WELDING

and, therefclrr, ~.hc~uld

be

the fir5.t pclint checked

whef-1

probl

emE.

occur.

-

Check

that

the

shieldinq

gas.

ic. cc~rrect for

the

electrode wire

in

use

and

for

correct

gas

flow

rate

at

the welding torch nozzle.

Ensure

there

are

no

gas

1

eakc.,

as.

this

wi

1

l

resul

t

in

we1

d

pclrosi

t;~,.

The

gas

nuzzle

must

be

free

from

spatter

and firmly attached

to

the

welding

nozzle

to

ensure

that

atmctspheric gas.

is

nc~t dra,wn intct

the

shielding

gas.

-

Estatll

ish

that

the

arc

{JOI

tage

is

correct

1

y

5.et

An

arc

I,JCI~

tage

which i

5

too

1

ow wi

1 1

cause excec.c,i

{le

crack1

e

I

shorting

and

spat

ter

,

wh

i

1

e

an

arc

uul

tage too high

may

resul

t

i

rl

el

d undercut and/or

loss of arc “direction’.

Arc

length is proportional

to

arc

I,JOI

tage.

-

l.pJctr

k

-p

i ece

5.u

r

f

ac e

c

on

tam

i

na

t

i

on

by

wa

t

er

cti

1

,

grease,

galuanising, paint,

or

oxide

layers

can

severely

disturb1 the

we1

di rig arc

rec.ul

t

in9 in

a

poor.

we1

d

deposi

t

.

Shou

1

d

t

h

i

S

condition occur, surface cleaning

c?f

the

work

piece

wi1

1

be

n

ec

esc,ar

Y

.

,

WELDMATIC

180s

MANUAL

PAGE

i

l

“

7.2

NO

WELDING

CURRENT

-

Check

that

Mains

Supply

is.

auailatlle

at

the

WELDMATIC

188s

Power

Source,

i.e.,

that

the fan

is

running and

the indicator

light

is

on.

-

Check continuity

of

the

welding current circuit, i.e.y

work

lead,

work

clamp

and gun cable connections.

-

Inspect,

and replace

if necessary fuses on

the

WELDMATIC

i86zs

Power

Source front

panel,

Replace fuses only

with

the

correct

type

(3AGi)

and

correct current

rating.

-

Check operation

of

the welding gun cwitch, i.e.

,

wir~?-t”eed

motor

runs,

and

gas

val

ue

CIFIerates

when-

gun

sui

tch

c

1

osed.

I

f

not

replace

the

gun cable

assembly,

and

re-test.

-

If

the

forgoing

checks

haue

tleerl

made

.md

not revealed

the

Saul

t

condition

it

is

possible

that

a.

failure

has

occurred in

the

electronic control circuits of the

WELDMATIC

1538s

.

In

this instance,

QUALIFIED

SERVICE

PERSONNEL

should

refer

ts

the

in-formation contained in the fc11 1c11~~inq Section.

WELDMATIC

180s

MANUAL

PAGE

12

-

8,

CONTROL

PRINTED

CIRCUIT

BOARDS

-

8.2

WIRE-FEED

CONTROL

BOARD

W1A-21

The

PCB W16-ZI

in

conjunction

with

PCB

Wid-28

perfctrmc,

the

fol

lclwinq

f

uric

t

i

onc.

:

-

Closed-lc~ap

speed

cclntrol

fur

the

wire

feed

motclr.

-

Run,

and

braking

control

of

the

wire

feed

mator.

-

Driver

for

the

gas

c.ct1enc~id valve.

-

"Burn-back"

of

the

electrode

wire

at

end

af

weld.

It

a1

5.0

pravides

the

el

ec

trieal E.cIcket5.

to

a1

1

c~w

pctst-f

i

t

of

vdricIu5

W14

wire-feeder

'Options'

such

a5

:

3OY.

AC SUPPLY

UTILUX

HIPP6

U.

. .

.

F1

GURE

7.

W1

RE-FEEDER

MOTHER

BOARD

pcS

OUERLAY

W1

6-21

-

c

WELDMATIC

18Gis

MANUAL

PAGE

13

0

;I

3

c5

00

cb

U

Y

FIGURE

3

WIRE-FEEDER

SPEED

BOARD

PCB

OIJERLAY

W1

6-20

WELDMATIC

i805

MANUAL

PAGE

14

This

tmard

detects

welding

current

initiation

and

times

the

Spat

Welding

and

Cycle

Arc

operation.

>l-1-1-1-

k

WELDMATIC

180s

MANUAL

PAGE

15

eSPAREEm3LL.i

”

9.1

POWER

SOURCE ASSEMBLY

ITEM

3

PART

3

1

2

3

4

5

L

7

8

8.1

9

16

11

12

13

14

15

16

17

15‘

17

28

21

22

Lb

24

25

26

27

’

28

2

P

38

,l

31

.1

31.2

31.3

31.10

32

33

34

35

36

37

38

37

48

41

cc

CP17-29

CP17-25

CP17-28

CP17-11

Wid-21

W1

6-20

W1

1-28

CP1

7-8/Y

CPi7-6/16

CPl7-6/11

W

1

-23

CP15-61/4

CP17-B/14

CP1

5-6/14

W1

1

-8/‘i

6

k15-16/19

CP28-

1

4/‘

1

8

W

1

-33/

1

W1

1-1

1

W1

7-1

4

TC262

TC262N

C:P17-1

1

CPL 7-36

CP17-14

CP17-16

CP17-17

CP17-6/38

w1-19

CPf

7-8/31

Id1

7-8/‘1

1

IJ

1

7-6,’

1

3

W1

1-82/15

Ard

128-50

Ar113-14

W

I

rd

4

Am

m-3

AA35

(MC1 4-6/18

<MC

1

4-8~9

1

CP17-8/36

GP

l

7-8/37

CP1

7-8/38

W1

1-8/13

AM97

CP17-@1/4i

DESCRIPTION

BASE ASSEMBLY

TRANSFORMER ASSEMBLY

LIMITING

BC

WELDING INDUCTANCE ASSEMBLY

RECTI F1 ER ASSEMBLY

WIRE-FEEDER MOTHER

BOARD

PCB

W1

RE-FEEDER SPEED

BOARD

PCE

SPOT TIMER/’CYOLE ARC

BOARD

PCB

CURRENT RELAY

CO1

L

REED RELAY

CONTROL TRANSFORMER 248-31VF 226UA

CONTACTOR

VOLTAGE SWITCH

FUSE HOLDER

FAN

BLADE

FAN

MOTOR

2400 56 Hz

CONTROL PLUG

TYPE bIO./SERIAL

NO.

NAMEPLATE

KNOB

-

bJ1

RE

SPEED

KNOB

-

SP@T/’CYCLE

PCB

PlOUNT

I

NGS

GAS

VALVE

HOSE

GARB

GAS

VALVE CONNECT1

ON

GAS

HOSE NIPPLE

NUT

FRONT PANEL

BACK

PANEL

BAFFLE

BC

COWONENT

MOUNT

I

NG

PANEL

TOP COUER

SI DE PANEL

LOOM ASSEMBLY

-

POWER SOURCE

OFF/ON

SWITCH

LOOM

AssErIBw

-

WI

RE

FEEDER

I

rm

I

CATOR

L

I

GHT

INCH/PURGE SWITCH

W1

RE

SPEED

POTENTI

OtIETER

SPOT/CYCLE

SELECTION SI*!ITCH

GAS

HOSE

OUTPUT TERtlINAL ASSEMBLY

CABLE ENTRY BUSH

CABLE

ENTRY

BUSH

CASTOR WHEELS

FIXED WHEELS

HOSE PLUG

SUPPLY FLEX

CAPAC

I

TOR

BOTTLE CRADLE

ASSEMBLY

HANDLE

.

WELDMATIC

188s

MANUAL

PAGE

16

9.3

WELDMATI

C

118s

MANUAL PAGE

l7

TWO-ROLL-DRIVE ASSEMBLY

ITEM# PART

3

i

2

3

4

5

6

7

8

9

18

11

12

13

14

1';

16

17

18

15'

26

21

22

23

24

25

26

27

28

29

36

31

32

33

34

35

36

37

W2-44/1

w2-44/2

b52-44/25

W2-17

W2-44/&.

W2-44/'13

w2-44/7

W2-44/8

w2-15

w2-44/9

03r356ZP

W

2

-

1

6

WZ-,

.

W2-44/12.

.

W2-44/2X

W2-44.>'22

LJ2-44/5

w2-44/21

4928

W2-44/.1

9

W2-44./26

DESCRIPTION

2

ROLL

DRIVE

BODY

2

ROLL DRIUE TOP ROLLER HOUSING

SHAFT

SOCKET SET SCREW

1.15

x

18

WASHER

M5

STAR LOCK WASKER

SOCKET HEAD SHOULDER SCREW

M8

x

26

BELLE01 LLE WASHER JW417

SPRING

NUT

TOP

ROLL

SHAFT

1.18

x

48

S.H. SHOULDER SCREW

BEAR

I

NG

60

82

2

BEARING FL6C-rEZZ

M6

HEXAGONAL DOME

NUT

DRIUEN GEAR WHEEL

TOP ROLLER BUSH

aL.REW

NO.

8-32

X

1

/2"

LING:

S0C.K

,

CAP

HEAD

CAP

HEAD

SOCKET

SCREW

rm

X

10

TENS1

ON

ARM

'

0-

DRIwrdG

GEAR

WHEEL

SLOTTED

PAN

HEAD

SCREW

rl3

x

e;

CAP

HEAD SOCKET

SCREM

M5

>:

15

CAP

HEAD

SOCKET

SCREW

1.16

x

12

C/SUNK

HEAD

SOCKET

SCREW

r.16

X

12

DRIVE ROLLERS

-

SEE TABLE

WIRE INPUT GUIDE

-

SEE

TABLE

ADAPTER

BUSH

LOCKNUT

P124

x

1

CAP

HEAD

SOCKET

SCREW

1.18

X

2s

SPRING WASHER 5'1

6"

CAP

HEAD

SUCKET

SCREW

rw

>:

1s

FLAT WASHER

5/

1

6"

I

NSLILAT

I

biG

R

I

NG

FLAT MASHER 24mm

I

.D.

x

34mrr1

O

.D.

BERNARD

QUI

Cl<

CONNECT

BERNARD CABLE ADAPTER

GLlI DE TUBE

i

FIGURE

i

l.

TWO

ROLL

DRIVE

ASSEMBLY

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WIA Weldmatic 180S Owner's manual

WIA Weldmatic 180S Owner's manual

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