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 designed for Gas Metal Arc Welding (GMAW), commonly known as MIG welding. It offers precise control over welding parameters, making it suitable for a wide range of welding applications, from sheet metal to heavy plate. With a welding current range of 35-250 Amps, it can handle various wire diameters from 0.6mm to 1.2mm. The machine features separate coarse and fine voltage controls, allowing for precise adjustment of the welding voltage, and a wire speed control for setting the welding current.

WIA Weldmatic 250S is a versatile welding machine designed for Gas Metal Arc Welding (GMAW), commonly known as MIG welding. It offers precise control over welding parameters, making it suitable for a wide range of welding applications, from sheet metal to heavy plate. With a welding current range of 35-250 Amps, it can handle various wire diameters from 0.6mm to 1.2mm. The machine features separate coarse and fine voltage controls, allowing for precise adjustment of the welding voltage, and a wire speed control for setting the welding current.

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
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
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.
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
c
II
l
t
tt
."
>
m
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
WELDMATIC
250s
MANUAL
Page
l9
'1
Iy.
L
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

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

WIA Weldmatic 250S is a versatile welding machine designed for Gas Metal Arc Welding (GMAW), commonly known as MIG welding. It offers precise control over welding parameters, making it suitable for a wide range of welding applications, from sheet metal to heavy plate. With a welding current range of 35-250 Amps, it can handle various wire diameters from 0.6mm to 1.2mm. The machine features separate coarse and fine voltage controls, allowing for precise adjustment of the welding voltage, and a wire speed control for setting the welding current.

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