WIA Weldmatic 250S Owner's manual

WELDING

INDUSTRIES OF AUSTRALIA

A

DIVISION

OF

WELDING INDUSTRIES

LTD

ACN

004

547 1

l

'l

Head

Office

and International Sales

5 Allan

Street,

Melrose

Park

South

Australia, 5039

Telephone

(08) 8276 6494

Facsimile

(08)

8276 6327

OWNERS

MANUAL

WELDMAPIC

250s

MODEL

NO. CPIOB-I,

REV.

E

WITH

W39-0

WIREFEEDEW

03/99

QUALIN WELDING PRODUCTS,

SYSTEMS

AND

SERVICE

Page

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

.

Failure 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 WIREFEEDER is

DO 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

Sec.4

...........

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

Sec.9

...........

Trouble Shooting

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

P

.

11

Sec

.

10

.........

Service Information

.

Power Source

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

P

.

13

Sec

.

l

.........

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.3

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

Positive Wire Connection

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

P.7

Fig.4

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

Negative Wire Connection

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

P.7

Fig.5

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

"Good" Weld

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

P

.

-l

0

Fig.7

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

Gun Position

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

P

.

10

Fig.8

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

Solid State Relay Control Board

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

P

.

13

Fig.10

..........

CP106-1 Circuit Diagram

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

P

.

16

Fig

.

12

..........

Wirefeed Control Board

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

P

.

18

Fig.13

..........

W39-0 Circuit Diagram (With Lead Kit)

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

P.19

Fig.14

..........

Wirefeeder Assembly

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

P.21

Fig

.

15

..........

Gun Cable Assembly

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

P.22

Fig.16

..........

Wire Drive Assembly

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

P.23

Fig

.

17

..........

AM280 Inter-connecting Lead Kit

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

P.24

Fig.2

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

Connection of Supply Cable

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

P.6

Fig.6

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

"Bad" Weld

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

P

.

10

Fig.9

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

Power Source Assembly

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

P.15

Fig.11

..........

Remote Wirefeeder Connections

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

P.17

WELDMATIC

250s

MANUAL

Paae

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 shietded 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 such as AUSTMIG €S6 is used with a shielding gas of

Argon mixed with

5

-

25%

Carbon Dioxide. Alternatively, Flux-cored consumables 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 CP106-l package contains;

WELDMATIC

250s

Power source.

W39-0

Enclosed Wirefeeder (with Controls).

AM280-0/8 Inter-connecting Lead Kit,

8

metre.

BEXT2-4E31OAE BERNARD Gun cable,

3

metre, Euro connector.

WGAC24 Regulator and Flowgauge. (Argon)

H

(This) Owners Manual.

c

3.

SPECIFICATIQNS

Manufactured to Australian standard AS1 966.1-1

985

PRIMARY VOLTAGE

480

Vac, Single Phase

50

Hz.

RATED PRIMARY CURRENT

10

Amps

MAX

PRIMARY DEMAND

20

Amps

FUSE WTlNG

20

Amps

SUPPLY CABLE 30/0.25 Three Core, Heavy Duty

WTED OUTPUT

250

Amps

@

26.5V

18%

Duty Cycle

WIRE SIZE WNGE 0.6mm

-

1.2mm diameter

OPEN CIRCUIT VOLTAGE Maximum

44

Volts

.WIRE SPEED RANGE

1

to

15

Metredmin

WELDING CURRENT

RANGE

35

-

250

Amps

CQOLING Fan cooled, air drawn in

through rear panel.

INSULATION Class

H,

140°C Rise.

Duty cycle

is

defined in Australian Standard ASl966.1

as

the ratio

of

arcing time

to

Note. Australian standards allow the circuit breaker or fuse supplying

a

welder to

(AS3000,

clause

2.4.3.4).

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

Page

5

4.

CONTROL

LOCATIONS.

POWER

SOURCE AND

WIREFEEDER

t

POWER SOURCE WIREFEEDER

FIGURE

1.

CONTROL LOCATIONS.

POWER

SOURCE

AND

WIREFEEDER

l.

POWER ON 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

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

When operating the machine in Spot

Weld

mode, this control will 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.

FITTING

THE

GAS BOTTLE

Depending

on

configuration

of

the cylinder to

be

used, the

gas

flowmeter

I

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

sf

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.

The

WELDMATIC:

250s

is

factory

fitted with

a

3

metre,

3

core

38/0.25

Heavy Duty

PVC

mains power supply

cable.

The

recommended Supply

Fuse

rating is

30

Amps.

Due to peak current

requirements, the Electrical Mains

supply

to welding machines

is

best protected by

fuses. Circuit Breakers may trip frequently

if

used in this application.

This

cable

should

be

correctly connected

to

8

suitable

480Vac,

28

Amp

Single

Phase plug or fixed connection point.

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]

EARTH

CONNECTION

1

\GREEN/YELLOW

WIRE

MINAL

BLOCK

L

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, hert 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

2505

allows external selection

of

the output

Y

o@

WELD

LEAD1

uu

FIGURE

3.

POSITIVE WIRE

FIGURE

4.

NEGATIVE WIRE

Page

8

WELDMATIC

250s

MANUAL

6.

NORMAL WELDING SEQUENCE

WELD

START

:S

:

Closing the welding gun switch initiates this sequence of event

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.

The wire drive motor

is

energised. Wirefeed commences and the arc

is

established.

WELD

END

Releasing the gun switch initiates this sequence

of

events:

m

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 Figure/Section

11.

The gas

valve

is

de-energised and the flow 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

:

used. Many proprietary shielding gas mixtures are available.

Mild Steel

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

Argon

+

5

to

25%

Carbon Dioxide;

Aluminium

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

Argon;

Stainless Steel

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

Argon

+

1

to

2%

Oxygen.

Consult your gas supplier if more specific information

is

required.

WELDMATIC

2505

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

litredmin.

In

situations where draffs..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 consumabte 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

wili

be long with the metal transfer within the arc

occurring as a series

of

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

2505

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.

L

1.

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 normally positioned as shown in Figure

7

FIGURE

7.

GUN

POSITION

L

WELDMATIC

250s

MANUAL

Paae

1

l

8.

GENERAL

MAINTENANCE

DUST

Care should be taken to prevent excessive build-up of dust and dirt within the

welding power source.

It

is recommended that at regular intervals, according to the

prevailing conditions, the machine covers and enclosed wirefeeder.covers be removed

and any accumulated dust be removed by the use of dry, low pressure compressed air,

or

a

vacuum cleaner.

WIREFEED

In

order

to

obtain the most satisfactory welding results from the

G.M.A.W.

process,

the wirefeed must be smooth and constant.

It

is therefore important

to

observe the

following points;

Keep the gun cable liner clear of

dust

and swarf build-up. When replacement

becomes necessary,

fit

only the correct liner

to

suit the gun cable model. See

Section

1

-l.

The build-up of dust in a cable liner

can

be minimised by regular

purging of the liner with dry compressed air. This may be conveniently done each

time the wire spool is replaced.

Replace the welding tip as it becomes worn.

m

Keep the wire drive mechanism ciean. Periodically check the drive rollers for

wear and for free rotation.

Check that the consumable wire spool holder rotates smoothly and that the

braking action is not excessive.

This

also may be conveniently done each time the

wire is rep[enished.

9.

TROUBLE

SHOOTJNG

UNSATISFACTORY RESULTS

WIREFEED

Erratic wirefeed

is

the

MOST

LIKELY

cause of 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.

h-

.

Check that the shielding gas selected is correct for the consumable wire in use.

WELDfNG

CIRCUIT

Ensure that the work clamp

is

securely tightened onto the work piece

so

that

good electricat contact is achieved. Check also that the output.poiarity 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

2505

MANUAL

WIREFEED

I

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 vottage is

too

high to suit the

wire

speed. To

correct this, increase wire speed or decrease arc voltage.

NO

WELDtNG 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.

WELDMATtC

2505

MANUAL

Page

l3

IO.

SERVICE

INFORMATION.

POWER

SOURCE

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

ONlOFF

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.

L.E.D.

IS

LIT WHEN FINE VOLTAGE POTENTIOMETER CIRCUIT

IS

COMPLETE

l

I

FINE VOLTAGE

ICW)

FINE VOLTAGE

(W)

SOLID

STATE RELAY

(+VE)

SOLID

STATE RELAY (-'/E)

RECTIFIER THERMOSTAT

CONTROL

30V

AC

I

Connections to the board are detailed in the drawing below.

.\

FIGURE

8.

SOLID

STATE

RELAY

CONTROL

BOARD

Page

14

WELDMATIC 250s MANUAL

l

l.

PARTS

LIST

WELDMATIC

250s

POWER SOURCE

ITEM

#

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

PART #.........................DESCRIPTION

1

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

..CP106-10

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

PCB Assembly Solid State Relay Control

2

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

CP106-0/1

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

Rectifier Assembly with Thermal overload

3

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

CPI 06-1/2

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

Solid State Relay

4

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

CPIO

6-60

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

Welding Transformer Assembly

(480V)

7

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

..CPlQ6-34

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

Capacitor Bank

5

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

CPI 06-29

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

Inductance Assembly

6

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

.CP102-l7

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

Limiting Inductance

Includes

7.1

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

CP102-12/8

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

Capacitor (4)

7.2

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

CP106-48

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

Heatsink

7.3

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

CP101-34/1

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

Thermostat (63oC)

8

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

CPIO 6-21

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

Base Assembly

8.1

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

CP42-24/6

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

Castor Wheel (2)

Includes

9

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

CP106-22Y

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

Front Panel

IO

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

CP106-23Y

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

Back Panel

11

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

CP106-24

side de

Panel (2)

12

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

CPlQ6-25Y

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

Top

Panel

13..

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

CP106-26

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

Shelf Panel

14

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

CP106-28

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

Rectifier Mounting Bracket

15

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

CP42-0/3

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

Rubber Tyre Wheel (2)

17

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

..MK6/6

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

Terminal Block, 6 position

16

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

..,MC1 1

-53/6.

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

Ratchet Cap (2)

18..

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

..CP27-0/15

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

Cooling Fan (2)

19

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

CP101-0/17

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

Fan Finger Guard (2)

20

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

.CPlO6-1/1

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

.Auxiliary Transformer

21

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

CP38-31/6

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

Fuse Holder

(2)

24..

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

CPI 06-20/2

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

Discharge Resistor

(4)

25

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

CP106-37

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

boom

Assembly (High Voltage)

26

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

CP106-36

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

Loom Assembly (Low Voltage)

22.

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

FUS5A3AGD

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

Fuse (2)

23.

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

W39-0/1

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

Coarse Range Switch

Includes

26.1

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

CP3U"

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

Socket 8 pin

27

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

H774

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

Cup Terminal

28.

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

.H774W

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

Washer

29

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

H285

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

Earth Tab

30

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

H906

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

Cable Clamp

31

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

.MC1 4-011

0

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

Mate

Insulating Bush

32

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

MC1 4-0/11

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

Female Insulating Bush

33

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

CX58

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

Output Terminal Assembly

(2)

34.

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

.SCG038...

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

Steel Chain 650mm

35

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

CAB3C30HD

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

Mains Cable

36..

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

..CP42-39

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

Handle Assembly

WELDMATIC

250s

MANUAL

Page

l5

I

/

d

FIGURE

9.

WELDMATIC

250s

POWER

SOURCE

ASSEMBLY

Page

16

.

WELDMATIC

250s

MANUAL

L-

L

3

L

m

c

II

l

t

tt

."

>

m

-1

@L1

-l-

m

cc

-Ia

Ln

UN

FIGURE

10.

CP406-1

CIRCUIT

DIAGRAM

L

WELDMATIC

250s

MANUAL

Page

l7

12.

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 BEXT2-4E31OAE 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

W394

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

WIRE

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 ES6. Dirty, rusty

or

kinked wire will not feed smoothly through the gun

cable and

will

cause erratic welding. Deposits from the wire wit1 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 spool brake, which should be set to prevent over-run of the

wire spool

at

the end

of

a

weld, without unduly loading the wirefeed motor. The braking

can

be adjusted by the Nyloc nut using a 15/16" AF or 24mm socket wrench.

FEEDING THE

CONSUMABLE

WIRE

With reference to Figure 16, release the pressure screw (1

01,

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 roller, 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.

Do

not over tighten.

GAS CYLINDER

&

REGULATOR

K

\GAS HOSE

W/f WELDING CABLE

'CONTROL

CABLE

FIGURE

91.

REMOTE

WIREFEEDER

CONNECTIONS

Page

18

WELDMATIC

250s

MANUAL

WIREFEED

CONTROL

BOARD

CP105-10

The Wirefeed control board provides the following circuit functions, when Power

Source is connected to Wirefeeder:

Wirefeed motor

ON

/

OFF

control

in

response to the gun-switch.

m

Speed control of the wirefeed motor.

m

'Burn-back' control.

g

Braking of

the

wirefeed motor

at

end

of

weld.

Spot-weld timer.

Interval timer.

Control of the gas solenoid valve.

Connections to the board, and Service points are detailed in the drawing below.

The circuit

is

factory adjusted to provide

a

maximum drive roller speed

of

160

rpm.

SOLID

STATE RELAY

-

30

TO CONTROL T/F

{$;

SOLID

STATE RELAY

-(l

GAS

VALVE

<

1

L

0

CP105-10

,

WIREFEED

MOTOR

}WIRE

SPEED

POT.

)POWER

'ON'

LED

-SOLID

STATE RELAY

>GUN

SWITCH

)SPOT

TIME POT.

>INTERVAL POT.

BURNBACK ADJUSTMENT

L

MOTOR RUN/BRAKE RELAY

FIGURE 12.

WIREFEED

CONTROL

BOARD

L

WELDMATIC

250s

MANUAL

Page

l9

'1

Iy.

L

c

C

or

3-

3

U

0

U

cl

L

0

I

WC

1

FIGURE

13.

W39-0

WIRE FEEDER

CIRCUIT

DIAGRAM

(WITH

LEAD

KIT)

L

c

13.PARTS

LIST’

W39-0

WIREFEEDER

(WITH

CONTROLS)

ITEM

#

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

PART

#

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

DESC~ lP.lON

1

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

.CPlQ5-10

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

PCB Assembly Wirefeed Control

2..

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

W39-1 1

Y

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

.Base Panel

3..

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

W39-12Y

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

.Front Panel

4..

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

W39-13Y

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

Back Panel

5

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

W39-I 4Y

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

Top/Side Panel

6

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

W39-15Y

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

Door Panel

7’.

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

W39-I

6Y

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

Divider Panel

8

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

W40-1

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

Motor and 2

Roll

Dr

9

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

MC1 1-3212

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

Insulating Bush (2)

IO.

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

W39-17.

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

Motor Insulator

(2)

l1

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

TC396-l

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

Euro

Adaptor

12

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

CP101-U18

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

Gas

Valve

13

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

W1 1-1 1/1

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

Hose

Tail (2)

14

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

OCL8

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

’0’

Clip 5/16”

-ive

15

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

AMI77

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

Spool Holder Assembly

15.1

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

AM133-3

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

‘R’

Clip

Includes

16..

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

W39-18..

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

Loom Assembly

16.1

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

CP34-3612

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

.Potentiometer,

l

K

Includes

17.

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

W39-19.

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

Loom Assembly, Wirefeed Motor

18..

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

W39-20..

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

Loom Assembly, Fine Voltage

l

g...

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

W39-21

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

Loom

Assembly, Wirefeed PCB

19.1

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

.CP27-41/26

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

.Potentiometer, 50K, Switched (2)

19.2.

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

W1 01 -1

l

/8

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

Potentiometer, 1

OK.

A Type

19.3

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

W1 7-0/11

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

indicator Light

Includes

20

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

HF200-1/15

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

Support Foot (4)

21

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

MC36-56/21

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

Male Bush

22

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

CP5-0/8

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

Female Bush

23

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

H907

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

Cable Clamp

24

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

Wd,l-O/l

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

Hinge

L.H.

25

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

W41-0/2

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

Hinge R.H.

26.

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

W29-1/20..

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

Slam

Action Latch (2)

27

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

W5-I 0/19..

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

Small Knob (2)

28.

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

W1 1 -0/16.

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

Large Knob (2)

29

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

S140-Q/1

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

Handle

30

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

CP102-0/18

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

PCB Support

(4)

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WIA Weldmatic 250S Owner's manual

WIA Weldmatic 250S Owner's manual

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