WIA Weldmatic 250S Owner's manual

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

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

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

mains plug (optional)

36

.....................

CP42-39

.......................

Handle Assembly

Includes

c

k

d

b

d

6

b

FIGURE

9.

WELDMATIC

250s

POWER

SOURCE ASSEMBLY

Page

16

WELDMATIC

250s

MANUAL

m

+

t

WE

ZQ

"""_

E

l

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

WIA Weldmatic 250S Owner's manual

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