WIA Weldmatic 250S Owner's manual

Weldmatic 250S
WIA
Brand
WIA
Model
Weldmatic 250S
Category
Welding System
Type
Owner's manual

WIA Weldmatic 250S is a versatile welding machine capable of Gas Metal Arc Welding (GMAW), commonly known as MIG welding. It's suitable for welding mild steel, stainless steel, and aluminum using the appropriate consumables and shielding gases. The machine offers precise control over welding parameters with its coarse and fine voltage controls, enabling users to dial in the perfect settings for their projects. The wire speed control allows for adjusting the welding current, while the spot time and interval controls provide flexibility for spot and cycle arc welding.

WIA Weldmatic 250S is a versatile welding machine capable of Gas Metal Arc Welding (GMAW), commonly known as MIG welding. It's suitable for welding mild steel, stainless steel, and aluminum using the appropriate consumables and shielding gases. The machine offers precise control over welding parameters with its coarse and fine voltage controls, enabling users to dial in the perfect settings for their projects. The wire speed control allows for adjusting the welding current, while the spot time and interval controls provide flexibility for spot and cycle arc welding.

WELDING
INDUSTRIES
OF AUSTRALIA
A
DIVISION
OF
WELDING INDUSTRIES LTD
ACN
004
547
l1
1
Head Office and International Sales
5
Allan
Street,
Melrose
Park
South
Australia,
5039
Telephone (08) 8276
6494
Facsimile
(08)
8276 6327
OWNERS
MANUAL
WELDMATIC
250%
MODEL
NO.
CP166-0,
REV.
F
WITH
W39-0
WIREFEEDEW
03199
QUALITY
WELDING
PRODUCTS,
SYSTEMS
AND
SERVICE
Paae
2
WELDMATIC
250s
MANUAL
The information contained in this manual is set out to enable you to properly
maintain your new equipment and ensure that you obtain maximum operating efficiency
.
Please ensure that this information is kept
in
a safe place for ready reference when
required at any future time
.
When requesting spare parts. please quote the model and serial number of the
machine and part number of the item required
.
All relevant numbers are shown in lists
contained in this manual
.
Faiture to supply this information may result
in
unnecessary
delays in supplying the correct parts
.
SAFETY
Before this equipment is put into operation. the Safe Practices section at the back
of the manual must be read completely
.
This will help to avoid possible injury due to
misuse or improper welding applications
.
PLASTIC
HANDLE
intended for carrying the machine by hand only
.
manner
.
Please note that the handle fitted to the WELDMATIC W39-0 WIREFEEDEK is
BO
NOT
use this handle for suspending or mounting the machine
in
any other
CONTENTS
Sec
.
1
...........
Introduction
............................................................
P.3
Sec2
...........
Receiving
...............................................................
P.3
Sec.3
...........
Specifications
.........................................................
P.4
Sec4
...........
Control Locations
.
Power Source and Wirefeeder
.
P.5
Sec.5
...........
Installation
..............................................................
P.6
Sec.6
...........
Normal Welding Sequence
....................................
P.8
Sec.7
...........
Basic Welding Information
.....................................
P.8
Sec.8
...........
General Maintenance
.............................................
P
.
11
Sec9
...........
Trouble Shooting
....................................................
P
.
11
Sec
.
IO
.........
Service Information
.
Power Source
........................
P
.
13
Sec.1 1
.........
Parts List
.
Power Source
........................................
P
.
14
Sec
.
12
.........
Service Information
.
Wirefeeder
............................
P
.
17
Sec.13
.........
Parts List
.
Wirefeeder
............................................
P.20
Sec 14
.........
Safe Practices
........................................................
P.25
FIGURES
Fig.1
............
Control Locations
.
Power Source and Wirefeeder
.
P.5
Fig.2
............
Connection of Supply Cable
..................................
P.6
Fig.4
............
Negative Wire Connection
.....................................
P.7
Fig.5
............
"Good" Weld
..........................................................
P
.
10
Fig.7
............
Gun Position
..........................................................
P
.
10
Fig.8
............
Solid State Relay Control Board
............................
P
.
13
Fig
.
1 1
..........
Remote Wirefeeder Connections
...........................
P
.
17
Fig.13
..........
W39-0 Circuit Diagram (With Lead Kit)
.................
P.19
Fig.3
............
Positive Wire Connection
.......................................
P.7
Fig.6
............
"Bad"
Weld
.............................................................
P
.
IO
Fig.9
............
Power Source Assembly
........................................
P.15
Fig.10
..........
CP106-O Circuit Diagram
.......................................
P
.
16
Fig
.
12
..........
Wirefeed Control Board
.........................................
P
.
18
Fig.14
..........
Wirefeeder Assembly
.............................................
P.21
Fig
.
l5
..........
Gun Cable
Assembly
.............................................
P.22
Fig.16
..........
Wire Drive Assembly
..............................................
P.23
Fig
.
17
..........
AM280 Inter-connecting Lead Kit
...........................
P.24
WELDMATIC
250s
MANUAL
Page
3
1.
INTRODUCTION
Gas Metal Arc Welding (G.M.A.W.) is a welding process where a consumable wire
is fed by motor driven drive rollers to a welding gun, and where welding current is
supplied from the welding power source. The welding arc is struck between the work
piece and the end of the wire, which melts into the weld pool. The arc and the weld
pool
are shielded by
gas
flow from the gun, or
in
the case
of
"self shielded" wires,
by
gases
generated by the wire core.
By
selection of the correct wire composition, diameter and shielding
gas,
G.M.A.W.
can be used
for
applications ranging from sheetmetal to heavy plate, and metals ranging
from carbon steel to aluminium alloys.
The WELDMATIC
250s
has been designed to be used with consumable wires
in
the range from 0.6mm to 1.2mm diameter. The smaller wire sizes are used when welding
at lower currents, such as sheet-metal applications. Increasing the wire diameter permits
higher welding currents to be selected.
A
common application
of
G.M.A.W. is for welding Mild Steel.
In
this application,
a
Mild Steel solid consumable suck as AUSTMIG €S6 is used with a shielding gas of
Argon mixed with
5
-
25% Carbon Dioxide. Alternatively, Flux-cored consurnables are
available
in
both gas shielded, and 'gasless' self shielding types.
Stainless steel and Aluminium can be welded with G.M.A.W. using the correct
consumable wire and shielding gas.
2.
RECEIVING
Check the equipment received against the shipping invoice to make sure the
shipment is complete and undamaged.
If
any damage has occurred
in
transit, please
immediately notify your supplier.
The
CPI
06-0
package contains;
WELDMATIC 250s Power source.
W39-0
Enclosed Wirefeeder (with Controls).
E
AM280-0/8 Inter-connecting Lead Kit,
8
metre.
BEXT2-4E31OAE BERNARD Gun cable,
3
metre, Euro connector.
WGAC24 Regulator and Flowgauge. (Argon)
(This) Owners Manual.
,
WELDMATIC
250s
MANUAL
3.
SPECIFICATIONS
Manufactured to Australian standard AS1 966.1-1
985
PRIMARY VOLTAGE
240
Vac, 50/6OHz 230 Vac, 50/6OHz
220
Vac, 50/60Hz
Single Phase Single Phase Single Phase
RATED PRIMARY CURRENT 21 Amps 21 Amps 21 Amps
MAX
PRIMARY DEMAND 46 Amps
42
Amps
38
Amps
FUSE
RATING(§ee note 1
.)
40
Amps 40 Amps 40 Amps
SUPPLY
CABLE(See note
2.)
50/0.25
(20
Amp)
Two
Core and Earth Heavy Duty
Fitted with
15
Amp, 3 pin plug.
RATED OUTPUT
250
Amps, 26.5V
230
Amps, 26V
21
5
Amps,
25V
20%
Duty Cycle
25%
Duty Cycle 30% Duty Cycle
WELDING CURRENT RANGE35
-
250 Amps
35
-
230
Amps 35
-
215 Amps
WIRE
SIZE
RANGE
0.6mm
-
1.2mm diameter
OPEN
CIRCUIT VOLTAGE Maximum
44
Volts
WIRE §PEED RANGE 1
to
15 Metredmin
COOLING
Fan cooled, air drawn
in
through rear panel.
INSULATION Class
H,
140°C Rise.
Duty cycle is defined
in
Australian Standard AS1966.1 as the ratio of arcing time to
Note
1.
Australian standards allow the circuit breaker or fuse supplying
a
welder
to
(AS3000,
clause 2.4.3.4).
Note
2.
To obtain rated output current from the WELDMATIC
250S,
the
20
Amp
flexible supply cable must be fitted with a
20
Amp,
3
pin plug, and connected
to
a
correctly installed
20
Amp power outlet.
The machine has been shipped with a 15 Amp plug fitted to allow initial
commissioning only.
20
Amp,
3
pin plug is available from your WIA distributor. (Part
No.
CLP43920TR).
5
minutes in any
5
minute period, expressed as a percentage.
be rated at up
to
twice
the
rated input current of
the
welder.
WELDMATIC
250s
MANUAL
Paae
5
4.
CONTROL LOCATIONS. POWER
SOURCE
AND WIREFEEDER
c3
c3
POWER
SOURCE
FIGURE
l.
CONTROL LOCATIONS.
POWER
SOURCE AND WIREFEEDER
l.
POWER
OM
INDICATOR
power is connected to the welding power source.
2.
COARSE VOLTAGE CONTROL
ranges, Low, Medium and High.
3.
FINE VOLTAGE CONTROL
control
in
a clockwise direction will increase the output voltage.
4.
WIRE SPEED CONTROL
This control provides adjustment of the wirefeed speed. Rotating the dial
in
a
clockwise direction will increase the wirefeed speed, thereby increasing the welding
current.
5.
SPOT TIME CONTROL
When operating the machine
in
Spot Weld mode, this control wit1 vary the spot
weld time. Rotating the dial
in
a clockwise direction will increase the spot weld time, in
the range
0.5
-
2.5
seconds. If the
Spot
Weld mode is not required this feature may be
turned off
by
rotating the control anti-clockwise until it 'clicks' into the minimum position.
6.
INTERVAL CONTROL
When operating the machine
in
Cycle Arc mode this control sets the period
between welds. The spot time control
sets
the welding period. Rotating the dial
in
a
clockwise direction will increase the interval time,
in
the range
0.5
-
2.5
seconds.
If
the
Cycle
Arc
mode
is
not required this feature may be turned
off
by rotating
both
controls
fully anti-clockwise.
This is illuminated when the wirefeeder is energised, that is when electrical mains
This switch provides Coarse adjustment
of
the Output Welding Voltage over three
This control provides Fine adjustment
of
the Output Welding
voltage.
Rotating the
J
WIREFEEDER
Paae
6
WELDMAPIC
250s
MANUAL
5.
INSTALLATION
FITTING THE GAS
BOTTLE
Depending on configuration of the cylinder to
be
used, the gas flowmeter
/
regulator may be fitted directly to the cylinder, or in conjunction with an elbow fitting.
DO
NOT
apply any grease to these joints, and tighten the nuts securely.
Fit the end of the gas inlet hose from the inter-connecting lead kit to the connector
supplied with the flow regulator, and secure with the clamp
also
supplied.
CONNECTION
TO
ELECTRICAL MAINS
POWER
SUPPLY
The WELDMATIC
250s
is factory fitted with a
3
metre,
3
core
50/0.25
Heavy Duty
PVC mains power supply cable with moulded
3
pin,
15
Amp, Single Phase plug.
To obtain rated output current from the WELDMATIC
250S,
the
20
Amp flexible
supply cable must be fitted with
a
20
Amp,
3
pin plug, and connected to a correctly
installed
20
Amp power outlet.
The machine has been shipped with a
15
Amp plug fitted to allow initial
commissioning only.
20
Amp,
3
pin plug
is
available from your WIA distributor. (Part
No.
CLP43920TR).
The recommended Supply Fuse rating is
40
Amps. Due to peak current
requirements, the Electrical Mains suppty to welding machines is best protected by
fuses. Circuit Breakers may trip frequently if used in this application.
If it becomes necessary to replace the mains power supply cable, use only cable
with correct current rating.
Access to the machine supply terminals is gained by removing the power source
left
hand
side panel. (Power source viewed from front).
Pass the cable through the bush fitted to the machine back panel. The cables are
terminated at the terminal block
as
shown in Figure
2.
Tighten the cable clamp leaving just sufficient slack
in
the cable
so
that the
terminated wires are not in tension.
BACK PANEL
7
CABLE CLAMP
7
BLUE WIRE7
r
BROWN WIRE
r
TERMINAL BLOCK
PLASTIC BUSH
I
EARTH CONNECTION
\
GREEN/YELLOW WIRE
FIGURE
2. CONNECTION
OF
SUPPLY
FLEXIBLE CABLE
WELDMATIC 250s
MANUAL
Page
7
OUTPUT VOLTAGE
POLARITY.
voltage polarity.
POSITIVE
WIRE
Most
solid
wire
G.M.A.W.
is carried out with the work piece Negative and the
welding consumable wire Positive.
To
set the machine
for
this condition, insert the
‘WORK
lead plug into the
(-)
output socket on the front of the power source. Insert inter-connecting
‘WELD’
lead plug
into the
(+)
output socket on the front of the power source. See Figure
3
below.
NEGATIVE
WIRE
Some ‘self-shielded’ flux cored consumables are intended to be operated with the
work piece Positive and the consumable wire Negative. Refer to the manufacturers data
for the particular consumable to be used.
To
set the machine for this condition, insert the
‘WORK‘
lead plug into the
(+)
output socket
on
the front of the power source. Insert inter-connecting
‘WELD’
lead plug
into the
(-)
output socket on the front of the power source. See Figure
4
below.
The design of the WELDMATIC
250s
allows external selection of the output
CONTROL
LEAD
FIGURE
3.
POSITIVE
WIRE
FIGURE
4.
NEGATIVE WIRE
Page
8
WELDMATIC
250s
MANUAL
6.
NORMAL WELDING
SEQUENCE
WELD
START
Closing the welding gun switch initiates this sequence of events:
The gas valve is energised, gas flow commences;
The power source contactor function is initiated. Welding voltage is applied
between the work piece and the consumable wire.
p
The wire drive motor is energised. Wirefeed commences and the arc is
established.
WELD
END
Releasing the gun switch initiates this sequence of events:
The wire drive motor is de-energised, and is dynamically braked to a stop;
After
a
short pre-set period, known as the 'burn-back' time, the Power-source
contactor function is released. This period ensures that the consumable wire does
not 'freeze' in the weld pool.
To
adjust the 'burn-back' time, refer to FigureEection
11.
R
The
gas
valve is de-energised and the ftow of shielding gas ceases.
7.
BASIC
WELDING INFORMATION
CHOICE
OF
SHIELDING
GAS
The choice
of
shielding gas is largely determined by the consumable wire to be
The recommended shielding gases for use with the WELDMATIC
250s
are
:
er
Mild Steel
...............................
Argon
+
5
to
25%
Carbon Dioxide;
used. Many proprietary shielding gas mixtures are available.
Aluminium
...............................
Argon;
Stainless Steel
.......................
Argon
+
1
to
2%
Oxygen.
Consult your gas supplier if more specific information is required.
WELDMATIC
250s
MANUAL
Page
9
SHIELDING
GAS
FLOW
RATE
In G.M.A. welding, one of the functions of the shielding gas is to protect the molten
weld pool from the effects of oxygen in the atmosphere. Without this protection the weld
deposit becomes 'honeycombed' in appearance, an effect which
is
described as weld
porosity.
In draft-free conditions the gas flow rate required to give adequate protection is
typically
IO
litres/min. In situations where drafts cannot be avoided,
it
may be necessary
to increase this rate and/or to provide screening of the work area.
Weld porosity can also be caused by air entering the
gas
stream through
a
damaged hose, loose gas connection, or from restriction in the nozzle, such as from
excess build-up
of
spatter.
ESTABLISHING
A
WELD SETTING
the two variables which are adjusted in order to obtain a stable arc are;
Once the consumable wire type, wire size and shielding gas have been chosen,
Wirefeed speed,
Welding arc voltage.
The wirefeed rate determines the welding current; increasing the feed rate
increases the current, and decreasing it decreases current. The selected wirefeed rate
must be matched with sufficient arc voltage; an increase of wirefeed rate requires an
increase of arc voltage.
If the voltage
is
too low the wire will stub and stutter, and there will not be a steady
arc.
If
the voltage is too high the arc will be long with the metal transfer within the arc
occurring
as
a series
sf
large droplets.
The welding current should be chosen to suit the thickness of the metal to be
welded.
It
is important to check that the deposited weld provides sufficient strength to
suit the application.
Paae
IO
WELDMATIC
250s
MANUAL
A
"good" weld will have the characteristics illustrated in Figure
5.
The weld has
penetrated into the parent metal, fusing the root of the joint where the two plates meet,
and the weld blends smoothly into the side walls.
A
"bad" weld, is shown
in
Figure
6.
The weld has not penetrated the joint root, and
there is poor side wall fusion. This lack
of
fusion would normally
be
corrected by
increasing the arc voltage, or by increasing both wirefeed rate and arc voltage to
achieve a higher current weld setting.
FIGURE
5.
"GOOD" WELD
FIGURE
6.
"BAD"
WELD
GUN POSITION
below with the nozzle end pointing
in
the direction
of
travel.
For "down hand" fillet welding, the gun
is
norrnally positioned
as
shown
in
Figure
7
FIGURE
7.
GUN
POSITION
WELDMATIC
250s
MANUAL
Paae
l
1
8.
GENERAL
MAINTENANCE
Check that the consumable wire spool holder rotates smoothly and that the
braking action is not excessive. Phis also may be conveniently done each time the
wire is replenished.
9.
TROUBLE
SHOOTING
UNSATISFACTORY RESULTS
WIREFEED
Erratic wirefeed is the
MOST
LIKELY
cause sf failure in all Gas Metal Arc
Welding. It should therefore be the first point checked when problems occur.
Refer
to
the section above.
Check for correct gas flow rate at the welding torch nozzle and ensure there are
no gas leaks. The gun nozzle must be free from spatter and firmly attached
to
the
welding gun
to
ensure
that
air is not drawn into the shielded area.
Check that the shielding gas selected is correct for the consumable wire in use.
Ensure that the work clamp is securely tightened onto the work piece
so
that
WELDING CIRCUIT
good electrical contact is achieved. Check also that the output polarity selected
is
appropriate for the consumable in use.
Contamination
of
the work piece surface by water, oil, grease, galvanising, paint,
or oxide layers can severely disturb the welding arc and result in a poor weld. The
contaminating material should be removed before welding.
Page
12
WELDMATIC
250s
MANUAL
WIREFEED
/ARC
VOLTAGE
RELATIONSHIP
If the consumable wire is stubbing into the work piece, and
a
steady arc cannot be
obtained, it is likely that the arc voltage is set too low
to
suit the wire speed.
To
correct
this situation either increase arc voltage, or decrease the wire speed.
If
the arc length is
too
long, the arc voltage is too high
to
suit the wire speed.
To
correct this, increase wire speed or decrease arc voltage.
NO
WELDING CURRENT
Check that Mains
Supply
is available
at
the WELDMATIC
250s
Power Source, i.e.
that the fans are running and the indicator light on the
W39-0
Wirefeeder front panel is
illuminated.
Check continuity of the welding current circuit,
i.e.,
work lead, work clamp and gun
cable connections.
The
WELDMATIC
250s
welding power source incorporates an in built over
temperature thermostat which will trip if the welding load exceeds the operating duty
cycle.
In
this event the machine will not deliver welding current until the machine has
cooled sufficiently. The thermostat will reset automatically
-
do
not switch the machine
off
as the cooling fan will assist the resetting of the thermostat.
If the forgoing checks have been made and have not revealed the fault condition, a
QUALIFIED SERVICE PERSON should be consulted.
WELDMATIC 250s
MANUAL
Page
l3
IO.
SERVICE
INFORMATION.
POWER
SQURCE
SOLID
STATE RELAY CONTROL
BOARD
CPlO6-IO
The Solid State Relay Control board and associated Solid State Relay provides the
following functions, when Power Source is connected
to
Wirefeeder.
Welding transformer OWOFF control in response
to
an output from the wirefeed
control board, (the contactor function).
Output voltage
control
by
means
of
Phase-shifting of the Welding transformer
primary voltage, as adjusted
by
the
wirefeeder front panel
"FINE
VOLTAGE
SELECTION" knob.
Connections to the board are detailed
in
the drawing below.
L.E.D.
IS
LIT WHEN FINE VOLTAGE POTENTIOMETER CIRCUIT
IS
COMPLETE
7
FINE VOLTAGE
(CW)
FINE VOLTAGE
(W)
SOLID STATE RELAY (+VE)
SOLID
STATE RELAY (-VE)
RECTIFIER THERMOSTAT
CONTROL
30V AC
I
U
1
FIGURE
8.
SQblD
STATE RELAY CONTROL
BOARD
9MATlC
250s
MANUAL
11,
PARTS
LIST
WELDMATIC
250s
POWER SOURCE
ITEM
#
.............
PART #.........................DESCRIPTIO.
1
.....................
..CP106-IO
.................
..,.PCB Assembly Solid State Relay Control
2
.....................
..CP106-0/1
....................
Rectifier Assembly with Thermal overload
3
.......................
CP106-0/2
..................
..Solid State Relay
4...
....................
CP106-50
.....................
Welding Transformer Assembly
5
.......................
CPlQ6-29
.....................
Inductance Assembly
6
.......................
CP1 Q2-17
.....................
Limiting Inductance
7
.......................
CPIO 6-20
.....................
Capacitor Bank
Includes
7.1
....................
CP102-12/8
..................
Capacitor
(4)
7.2
....................
CP106-48
.....................
Heatsink
7.3
....................
CP101-34/1
..................
Thermostat (63%)
8
.......................
CPIO 6-21
.....................
Base Assembly
8.
l
..................
..CP42-2416
..................
..Castor Wheel (2)
9
.......................
CP106-22Y
...................
Front Panel
IO
.....................
eP106-23Y
...................
Bacic Panel
1
l
.....................
CPI 06-24Y
.................
,.Side Panel (2)
12
.....................
CP106-25Y
...................
Top Panel
13..
...................
CP106-26
.....................
Shelf Panel
14
....................
.CP106-28
.....................
Rectifier Mounting Bracket
15
.....................
CP42-0/3
......................
Rubber Tyre Wheel (2)
16
.....................
MC1 1 -53/6.,
..................
Ratchet Cap (2)
17
.....................
MK6/2
...........................
Terminal
Block,
2
position
18
...................
..CP27-0/15
....................
Cooling Fan (2)
19
.....................
CPlOI-O/-l7
..................
Fan Finger Guard (2)
20
...................
..CP102-0/16
..................
Auxiliary Transformer
21
.....................
CP38-31-6
....................
Fuse Holder (2)
22.
....................
FUS5A3AGD
................
Fuse (2)
23
.....................
W39-0/1
.......................
.Coarse Range Switch
24
.....................
CP106-20/2
..................
Discharge Resistor
(4)
25
...................
..CP106-35
.....................
Loom
Assembly
(High
Voltage)
26..
...................
CP106-36
.....................
Loom Assembly
(Low
Voltage)
26.1
..................
CP34-0/14
....................
Socket
8
pin
27
.....................
H974
.............................
Cup Terminal
28..
...................
H774W
........................
.Washer
29
.....................
H285
.............................
Earth Tab
30
.....................
H906
.............................
Cable Clamp
31
.....................
MC1 4-0/1
Q
....................
Male Insulating Bush
32
.....................
MCl4-0/1
l
....................
Female Insulating Bush
33
.....................
CX58
.............................
Output Terminal Assembly (2)
34
.....................
SCG030
........................
Steel Chain 650mm
35
.....................
CP106-0/3
....................
Flex and Plug
35A
..................
CLP43920TR
................
20 Amp,
3
pin
mains plug (optional)
36
.....................
CP42-39
.......................
Handle Assembly
Includes
Includes
c
k
d
b
b
b
b
d
6
b
FIGURE
9.
WELDMATIC
250s
POWER
SOURCE ASSEMBLY
Page
16
WELDMATIC
250s
MANUAL
m
+
t
WE
ZQ
"""_
E
l
I
I
I
I'
FIGURE
IO.
CPlO6-0
CIRCUIT
DIAGRAM
l
WELDMAPIC
250S
MANUAL
I2
SERVICE
INFORMATION.
REMOTE
WIREFEEDER
The
W39-0
remote wirefeeder is connected
to
the
WELDMATIC
250s
Power
Source using an
AM280
inter-connecting
lead
kit. The connection details are shown in
Figure
13.
FITTING THE
GUN
CABLE.
The
BERNARD
BEXT2-4E310AE
gun cable is equipped with
a
'Euro' wirefeeder
connector which incorporates all required connection points to the
gun
cable for welding
current, shielding gas and gun switch control.
To
attach the gun cable to the
W39-B
wirefeeding mechanism, engage the mating
parts of the male and female Euro connectors, then rotate the locking ring clockwise to
firmly secure the connection.
FITTING
THE
CONSUMABLE
WRE
The quality
of
the consumable wire greatly affects how reliably a gas metal arc
welder will operate.
For
best results when welding mild steel, we recommend quality
WIA
AUSTMIG
€36.
Dirty, rusty or kinked wire will not feed smoothly through the gun
cable and will cause erratic welding. Deposits from the wire will clog the gun cable liner
requiring
it
to
be replaced prematurely.
Place the
spool
of welding wire onto the spool holder.
The
location pin should mate
with
a
hole provided on the wire
spool
body. Fit the spool retaining
'R'
clip
supplied.
Check the adjustment
of
the
spost
brake, which should
be
set to prevent over-run of the
wire
spool
at
the end
of
a
weld, without unduly toading the wirefeed motor. The braking
can
be
adjusted
by
the
Nytoc
nut using
a
15/16"
AF
or 24mm socket wrench.
FEEDING
THE
CONSUMABLE
WIRE
With reference to figure
16,
release the pressure screw
(l
0),
and rotate the
pressure arm
(8)
to the open position. The
end
of
the welding wire can now be passed
through the inlet guide, over the bottom driven rolier, and into the output wire guide tube.
Check
that the drive roller groove is correct
for
the
wire
in
use. The appropriate size is
stamped on the visible side of the installed roller. Check
also
that the correct size
contact tip
is
fitted at the gun
end.
Drive roller and tip details are available
in
Section
1
l
of
this manual.
Return the pressure arm to the closed position and, adjust the compression screw
to provide sufficient clamping of the drive rolls drive to achieve constant wirefeed.
Bo
not over tighten.
GAS CYLINDER
&
REGULATOR
7
-GAS
HOSE
\W/F
WELDING
CABLE
CONTROL
CABLE
FIGURE
11,
REMOTE
WIREFEEDER CONNECTIONS
WELDMATIC
250s
MANUAL
WIREFEED
CONTROL
BOARD
CP105-fO
The Wirefeed control board provides the following circuit functions, when Power
Wirefeed motor
ON
/
OFF control in response to the gun-switch.
Speed control
of
the wirefeed motor.
'Burn-back'
control.
Braking of the wirefeed motor at end
of
weld.
Source is connected
to
Wirefeeder:
Spot-weld timer.
H
Interval timet-.
Control of the gas solenoid valve.
Connections
to
the board, and Sewice points are detailed in
the
drawing
below.
The circuit
is
factory adjusted
to
provide
a
maximum drive roller speed
sf
160
rpm.
SOLID
STATE RELAY
-
TO
CONTROL
T/FrOo-
30
SOLID
STATE RELAY
<:
GAS VALVE
-(
1
I
Oh
)
WIREFEED MOTOR
}WIRE SPEED POT.
)POWER
'ON'
LED
-SOLID
STATE RELAY
)GUN
SWITCH
>SPOT TIME POT.
>INTERVAL
POT.
I
BURNBACK ADJUSTMENT
1
L
MOTOR RUN/BRAKE RELAY
FIGURE
12,
WIREFEED
CONTROL
BOARD
WELDMAT
C
2505
MANUAL
Page
19
l
W
WW
KW
-PI
n
l
3
U
c)
mm
UE
FIGURE
13.
W39-0 WIRE FEEDER CIRCUIT
DIAGRAM
(WITH
LEAD
KIT)
PageMANUAL
13.PARTS LISP
W39-0
WIREFEEDER
(WITH
CONTROLS)
ITEM
#
.............
PART #.........................DESCRIPTION
1
.......................
CPIQ5-10
....................
.PCB Assembly Wirefeed Control
2..
.....................
W39-1 1
Y
......................
Base Panel
3..
.....................
W39-12Y
.....................
.Front Panel
4..
.....................
W39-13Y
......................
Back Panel
5
.......................
W3 9-14Y
......................
Top/Side Panel
6..
.....................
W39-15Y
......................
Door Panel
7..
.....................
W39-16Y
......................
Divider Panel
8..
....................
.W40-1
...........................
Motor and 2 Roll Drive
9
.......................
MC1 1-3212
....................
Insulating Bush
(2)
IO
....................
.W39-17..
.......................
Motor Insulator (2)
11
.....................
TC396-1
.......................
Euro Adaptor
12
.....................
CP101-0/18
..................
Gas Valve
13
.....................
W1 1-1 111
......................
Hose
Tail
(2)
14..
...................
OCL8
.........................
...‘
0’
Clip
5/16”
15
....................
.AM1
77
..........................
Spool
Holder
Assembly
Includes
15.1
..................
AM1 33-3
......................
.‘RJ
Clip
16..
...................
W39-18..
.......................
Loom Assembly
16.
l
..................
CP34-36/2
....................
Potentiometer, 1
M
17..
...................
W39-19..
.......................
Loom
Assembly, Wirefeed Motor
Includes
18
.....................
W39-20.
........................
Loom Assembly, Fine Voltage
l9
...................
..W3921
.........................
Loom Assembly, Wirefeed PCB
19.
l
..................
CP29-11/26
................
..Potentiometer,
50K,
Switched (2)
19.3.
.................
W1 7-0/11
......................
Indicator Light
Includes
19.2..
................
CP1 01 -1 1
/8
..................
Potentiometer,
l
OK.
A Type
20
.....................
HF200-l /l
5
..................
Support
Foot
(4)
21
.....................
MC36-56/21
..................
Male
Bush
22
.....................
CP5-0/8
........................
Female Bush
23
.....................
H907
.............................
Cable Clamp
24..
...................
W41
-011
........................
Hinge
L.H.
25
.....................
W41-0/2
........................
Hinge
R.H.
26..
...................
W29-1/20..
....................
Slam
Action Latch
(2)
27.
....................
W5-10/19..
....................
Small Knob
(2)
28
.....................
W1 1-011
6.
.....................
Large Knob (2)
30
.....................
CP102-0/18
..................
PCB SUPPO~? (4)
29
.....................
S140-0/1
.......................
Handle
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WIA Weldmatic 250S Owner's manual

Weldmatic 250S
WIA
Brand
WIA
Model
Weldmatic 250S
Category
Welding System
Type
Owner's manual

WIA Weldmatic 250S is a versatile welding machine capable of Gas Metal Arc Welding (GMAW), commonly known as MIG welding. It's suitable for welding mild steel, stainless steel, and aluminum using the appropriate consumables and shielding gases. The machine offers precise control over welding parameters with its coarse and fine voltage controls, enabling users to dial in the perfect settings for their projects. The wire speed control allows for adjusting the welding current, while the spot time and interval controls provide flexibility for spot and cycle arc welding.

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