WIA Weldmatic Utility Owner's manual

MANLIFACTURED

BY

WELDING

INDUSTRIES OF AUSTRALIA

LTD.

HEAD OFFICE AND

EXPORT

DIVISION

're1

ept-,~ne

03

4d5-251.1

2-26

Austarc Avenue, Thcmastuwn

,

Facsirrti

1

e

83

465-863.2

Vic.

307'4,

Austral

ia

"e1

ex

AA32493

AUSTAHC

EQUI

PPIENT

MANUFACTURING DIVISION

Vel

ephclne

88

2?6-&4?4

ii2

Daws

Road,

Edwardstuwn,

Facsirrri

1

e

03

278-8383

S.A.

SOW,

Austral

ia

Tel

ex

AA82&5b

AUSTARC

SALES

AND SERVICE

SRANCHES

Adelaide ph

88

276

h888

t

1

X

AA82856

fax

88

276

4327

Br

i5bane

ph

07

844

1371

fax

87

844

6229

Launces.tan

ph

6183

44

P822

far,

883

44

6678

-SAFETY-

WELDMATIC UTILITY

MANUAL

PAGE

3

-~

INTAUDUGTION

GENERAL

This manual

has

been

preparecl

especially for

use

in

familiarising

personnel

with the design, instal lation, operation, maintenance,

and

truuble

shuo,t%ng

of

this equipment. A11 infurmation presented

17er-ein

51hould

be

given

careful corlt.;ideration

to

assure

optimum

performance

uf

this

equipmer-It.

RECE

L

V

I

NG/HANDL.

I

NG

Pr-iur

tu

i~stallirty this equipment, clean

all

packing

material

from

around

the

unit and carefully inspert for any damage that may

have

uecurr-ed

during sl-lipment. Rny

claims

far

losses

or-

damage that may

have

occurred

in

sllipment

must

be

filed

by

.the purchaser with

Wplding

Industrie5

of

Auskralia

Ltd.,

or

authorized

agerrt

itnmediately.

(Refer-

to

EWUIPMENT WARRANTY CARD

enclosed with this

Oper.a-t:iI-lg Manual

)

.

When

requesting infarmation soncerning this equipment,

it

is

essen'kial

to

supply cur-rcxt

MODEL

IDENTIFICATION

and

MACHINE

SERIAL

NUMBER.

CUNTENZ.

PAGE

GENERAL DESCRIPTIDN

..........

4

SETTING

UP

FOR OPERATION

.......

5

WELDING OPERATION INSTRUCTIONS

....

6

MAINTENQNCE INSTRUCTIONS

.......

8

WELDING DATA TAULE

..........

9

PARTS

LIST

CP1H-02

.........

.l0

ASSEMBLY

DRAWING

CP1&3--0

,

.

,

.

m

.11

CIRCUIT DIAGRAM

CP18-!22

.

I

. .

"12

ACCESSURY LEADS

...........

.l3

AM3.9:3

MOBILE

KIT

.

,

I)

,

.

.l4

SAFETY

PRACTICES

..........

.15

WFIHRANTY

CARD

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

.17

WELDMATIC UTILITY

MaNUFIL

PAGE

4

STANDARD

IJN

1.1-

The

construrtisn

of

the standard package plant

has

been designed

far in5tallatian and operating in

a

wide variety

of

applicatiuns,

such

as

high production factor-.ies

arid

general fabr-icatian shops.

"WELDMATIC"

Plant.; consi5.t:

of

three basic units:-

1.

Curts.trant Paterltial Recti.fier Power Source.

2.

Semi--Automatic Wire Feeder.

3.

Welding

Gun

and

Cable Assembly.

Separ'ate

oper-a-king

and maintenarlce instructions ar@ provided for

the wir-e

feeder

and gun cables.

"

1.

POWER

SOlJRCE

I-

FEATURES

The

standar-d CP rectifier power source

is

housed

in

a drip proof

e~~1~)sur.e. Lifting lugs

are

provided for crane transportation.

Fur

units

with

wheel meunting,

four

solid t:yred wheels

ar-e

provided,

tl~e

twu

front wheels ar-e .;terrable permitting easy

muvernent

in

restr-ic.trd

.fluor-

space!.

A

push bar-

is

provided

on

the

fI-on2:

of

the

machine and

a

gas

cylinder cal-r-ier

with

a support

br-acke2:

and

chain

at

the

reat-.

R

swivel meuntiny for the wire

feeder

is

fitted

to

.the

top

of

.the

puwer sour-ce.

A

110

volt plug

socket

is located on the rear panel for connectian

of

ga5

pruheatrr-

when welding with

CO2

yas shield. Located an the

front panel are

a

coarse voltage selection switch (incorporating

pawer

ON/OFF), .fine voltage seleetian switch, control fuses, wire

feeder- plug

socket

and

rectifier power output sockets.

2.

CONSTKUCTm

The

power-

~,uut-ce

is

a

Constant Potential Silicon Diode Rectifier

D.C.

W~lder-, with

a

three phase transformer and

a

three phase

t-eckifier

bridge.

Connected

in

the uutput circuit

is

an inductance

unit: providing the "inductance" or- degree

of

slope necessary

for

various welding currents. Cooling

of

the silicon diodes,

.tI-al-ldarrner- windi11gs

and

inductance

uni-t

is

by

a

single phase axial

far).

The power

source

is

pr-catected

against fan failure and

overheaking by

th~?rmo~ttats

mtsurlted

un

diode

heat sinks.

3.

WELDING

PROCESS

Gas

metal

arc welding within

the

capacity

of

the

power source can

be

carried

out

with

the folluwing equipment:-

a)

Semi-autarnatir

wire feeder

2

roll.

drive

Model

W17.

b)

~~II~.~'-i~~~.~UflI~~.~~

wire

feed~r

4

roll drive Model

WlS.

c)

Semi-automatic

wir-u

feeder

W17

or

W18

fitted

with

one

of

tl~e

fol lowing uptiwn kits:-

.

AM126

Pre and Post

ga5,.

.

AM127

Soft

stark

and

crater

fill.

AM928

Spat

timer

ancl

cycle arc

,

AM146

Push

and

pull gun and control,

control

1

er.

cl)

"Ho1~au.t" spool gun welding

unit

Model

§P9

with

CV2

4.

WELDING

CAPACITY

Power Saurce Capacity

i5

as

.follows:--

200

bps,

28

Volts,

100%

Duty Cycle.

250

Amps,

28

Volts,

60%

Duty Cycle.

WELDMAPIC UTILITY

MANUAL.

PAGE

9

-

5.

SUPPLY

AND

WELDING

CABLES

Pnwer-

Sources

are

suitab1.e

for-

connection to

a

415/440

Volt

50

Hz.

3

Phase supply.

The

recommended fuse

size,

primary

cablg

size and welding

cable

size

.are

as

follows:-

a)

Fuse

-

15

amp

b)

Primary

Cable

-

4

core

32/0.20

T.R.8.

c)

Weldiny

Cable

-

792/0.2@

T.R.S.

A.

SHIELDING

GASES

a)

Welding Grade

CO2

for

all

mild

and

a1l.oy

5teel

welding

in

tl~icknesses

ranging

from

lmrn

upwards.

b)

Clrgen/CQ2

or

Argen/Oxygrn mixtures

fer

all applications on

low

cur-r-ents

reyuiriny minimum

of

splatter on

shee.lr.

steel

and

for

stainle5,s

5teel

weldiny.

c)

nrqorr/Uxygen and

Aryon/CO2

mixtures

for

prime welding

uf

stainless

s.ke~?l

d)

Rrycan (pure)

for-

all

aluminium welding.

7.

SETTING

UP UNIT

FOR

OPERATION

a)

Grrleral

Assembly

of

Packaged

Plant

The power swur-c(?

is

sl-iiypud

on

its

skid

base.

Wheels.,,

handle,,

bottle

carrier

and

bwttle

cradle

should

be

assembled

a5

shown

in

drawing

8Ml93.

W17

Wire

Feuder-

is

fitted

to

the

top

of

power'

suurce

in

the

special

swivel

rrmunt

01-1

the machine.

Fit

the

W14-It,

pivot

assembly

to

ttje

wire

feeder

arld

ensure

fibre

thrust

washer

is

01.)

the

before

locating in

the

swivel rmun.I:iny.

Check

that

wire feeder

is

free

to swivel

in

all dir-ections,

if

necessary

apl~1.y

a

small amount

of

yr-aphite

yr-ease

to

shaft.

13)

Cur~~~ect~tiur~

tu

Mains

Supply

NOTE:

Thi%

wur-I<

shuuld

only

be

carried out by

a

qualified

electt-iriar\.

The

power siuurce

i.;

designed for connec.l:ior-l

to

415/440

Volt

50

Iiz.

3

Phase

supply

and

the supply voltage

5tlould

be

ascertained before

connerting

ttle

n~acl~ine.

Rcress

to supply eonnect.ion

terminals

in

cnactli.1-1e

may

be

gainvd

by

removing

left

hand

side

parlel.

Use

a

flexible

4

cor-^!

primary

cable

for-

portable machines

and

elamp

cable

to

ensure

that

thur-e

is

1-10

strain

01.1

cable

c~rlr~ections.

The earth

(or-

ground)

connectimn

(yreen/yel

10l.r)

must

be

securely

faskened

to

the

'uarth'

terminal on the machine adjacent to

the

supply

connection

.terminals.

Charlye

lir>k

on terminal

block

to

440

volt

position

if

rnac;Iline

is

coclnected

ta

440

Volt

supply.

CAUTION:

Before in5erting primary

cable

plug

in

mains

supply

sockd,

ensure

khat

switch

or1

both

plug

sacket

ancl

welding machine

is

.in

'CIFF'

position.

WELDMATIC

UTILITY

MfiNUFIL

PFIGE

6

c

)

Connectj.c)n

uf

Cables/Hnses

,

etc

,

With unit swit.ched

'OFF'

connect rontrel

cable

(4

plug)

from

pwwur

SQU~CE?

tu

wit-,

feeder-. Connect

gas

ho5;e from wire feeder

to

gas

regclls.tal-./-f.aowmE?t.er-,

ensuring

a1

1

connections

are

tightened

firmly.

If

CO2

Gas

Shi~2d

is

buriny

used,

plug

heater-

into

110

volt

soczket

at

real-

t1.f

unit.

Next insert

gun

cable into socket

of

wire

ft?e~Iev-

ou tput guide

Connect

"Gas

I-luse"

and

"Gun

Switch" leads

to

r-e.;pt'c'tive

surkets.

d)

Weldilly

Cables

All

G.M.R.

welding

is

done with

electrode

wire connected to

''pc35it:i.ve~~

pule

commonly known as

D.C.

rever'se

polarity

(D.C.R.P.

1

therefore

conllect

the short jumper lead

from

"+"

socket on machine

,to

.t:(?r-minal

lug

WI~I

yurl

cable.

The work lead ("rregative") should

be

pl.uyC)ed

ic~t:~

the

'I.-''

scacl<e~k

un

the

mael-line.

The

plugs

of

the

welding

cl:abJ.os

must

be

fully inserted in the

sockets,

to

prevent

accidental

disconneetion.

To

avoid error, weldirly should not

be

attempted

until

all

connections have been secure.

The

wire feeder-

may

be

installed

remote

from t:he power source,

in

which ca5e

oxten%ion

luad

s~ts

cmnprj.Eiing power

cable, gas

hose

and cot~trul

cable

(.four

cor-e)

are t-e~uired

in

accordance with the drsired

lerlyth,

~~tandard

length

available from stock

is

9

metres.

e)

Wire

Feeder-

and

Gun

Cable

Fi.t

a

spool

af

wire

to

the wire feeder

(5ee

rides

in

"Wire

Feeder

Znstructlon Manual")

Tighten the "brake" scr-pw until

a

slight

braking effect

i5

felt when turniny

the

wire

spool

by hand

to

prevent "over-run" when wire

fped

stops..

The

wire drive

rolls

and

inld wire guide should

be

5@1PCt€?d

in

accor-dance with the diameter

arid 'type

sf

wire being

used

Refer

to

current wir-e feeder manual

for correct selectiorl

sf

wire

feecl

r.-ollc~

and

ir1pu.l:

guides.

0

I

8mm

:=

0

.

030"

O.?rnm

=

0.035"

1

%mm

=

0.

45"

The gun

cable

and

gun

are

normally delivered

with

the

contact

tip

ancl

liner

spring

for wire size nominated, but check that

both

are

corrert

5ize

for wire

being

used.

WELDING OPERATION INSTRUCTIONS

Is_,

S

I

NGIs-_F_blNCT_.I

!JN

CHECK

Unit

is

now

ready

for operation, but prior

ts

commencing welding,

the

ful

lowing "functions check"

is

recommended:

Switch on power source and

check

air flow

-

See

that

all

welding

lead plugs

are

inser.ted

in

the

correct pularity

sc~clccts

-

electrode

"po.;it.i.ve", work "neyative"

--

Check

a1

1 welding connections and

plugs

for tightness par"Licu1ar1y "work" clamp.

.that:

all

control cables and

gas

hnses

are securely

cunr,ee.ted

atid .khat

Ga5

Heater (fer

CO2

only)

is

plugged

into socket

at

rear

of power

source.

Switch

nn

wir-u

feeder-, indicator light

should

now r,how "Power

On".

Open

gas cylinder

fully

and check

CotltEn'kEi

gauge

for-

&ldE?L~Ua'tP

gas

5UppI.y

WELDMATIC

UTILITY

MANUAL

PAGE

7

Press

"Gas

Purge" switch and set

gas

flow

in

accordance with

welding

requirements,

at

the

same

time,

check

that

gas

flow

(8-10

lt./min)

i5

adequate from

the

gun nozzle.

5et

"Wire Speed" control

ta de5.i.r-ed wire

speed.

PrE>ss "wire inch" switch and check wire

feed

for-

correct presrsure

on

drive

r-nlls.

Pressure should

be

su.ffisient to pr-event any "slip" when feeding through gun and

cable.

Nex-l:,

close

gun

switch

momentarily

for

wire

feed,

gas

flow and

wrlding

power

check.

Set

the

vol.

tage

selector switches

.in

arcor-dance

with

required

vtalt.age

(see

weldi.ng

table)

unit

is

now

ready

far

welding.

l~"""""l.-

9.

SETTING

OF

WELDING

CURRENT

4N-g

VOLTRGE.

Weldiny current is determined automatically by the 'wire speed'.

The electrode wir-o

i5

.fed

at

.the

pr-e-selected speed by drive rolls

-thr.c~ugfl

the

gun

cable

tu

Lhe

;arc

at

the

constar-It

speed,

a5

set

by

the

'wire

speed'

ccJntrc-,l. The higher the

wire

speed,

the

higher

the welcliny current

m

The

uutput

vol.taye

of

the

power

source whpn the gun switch

is

cla5ed,

.i5

divided into

a

number

uj:

steps

by

coarse

5elector and

fine

5electov.

switclhes.

The

'coarse'

selectur.

switch

is

a

cnfnk,j.r1ed

higt~~/low

r-arlge

ON/OFF

5wit.ch

wcarkiny

in

conjunction

with

a

"fine"

selector

switch giving 20

vultaye

~tep.;.

The

followillg

sequence

uf

weld setting

is

recommended:"

a) Consult typical

weld

settling chart.

b)

Select

weldiny cur-rer1.t most suited to the application by

fol

Iowing tthe settings

of

wire

speed

and

vultage shown on

the

setting

ehar-t.

To

"tune" each weld setting, adjust wire

speed

or)

ly

c)

If

voltage

is

too low for -the application wire "stubbing"

will

occur, part.icularly

at

stark

caf

weld and weld

contour

will

be very

convex.

If

t-11~

vul.t:age

is

too

high, metal ,transfer

will

be erratic

wi,th excess spatter-.

d)

With

welding

cur-rent

and

voltage matched ,the result

will

be

an

optimum

tuned

weldiny condition

with

a

smooth arc

wi.t:h

minimum

s.pd4-l:er-

formed

I

WELDMATIC UTILITY

MONUAL

PAGE

9

K€LD

1

NE

DATA

TflE-lE

TYPICAL

WELD

SETTING

CHART

WELDING

CURRENT (Amps)

I

30

40

50

60

70

80

90

100

120 140

160

180

200

220 24C

04mm

COARSE

VOLTS

1

l

1

2 2

2

2 2

2

WIRE

FINEVOLTS

3 3

3

4

6

10

1

2

3

8

10

I

D

WIRE

SPEED

CO

26 DIAL SETTING

1.3

1.4

2.0

2-4

2.5

3.1

3-9

4.5

4.8

5.9

6.7

10

0.9rnm

COARSE

VOLTS

111111222262

I

WIRE

FINE VOLTS 4446781334210

WIRE SPEED

CO

26 DIAL SETTING

1.2

mm

COARSE VOLTS

WIRE

FINE

VOLTS

1.3

1.5

1.7 109 2.2

2.4

3.0

3.9

4.6

6.4

1111122222

77779135810

SETTINGS

GIVEN

FOR

C02 SHIELDING

GAS -FLOW

RATE 8-tOLITRES/MlNUTE. USE

THIS

CHART

AS

A

PRELIMINARY SETTING

GUIDE.

TO'TUNE'

EACH

WELD

SETTING,

ADJUST

WIRE

SPEED

ONLY. FOR FURTHER DETAILS, INCLUDlNG

USE

OF

ARGON

MIXED

GAS REFER MANUAI

If

mixed

gasr5

are

to

be

used, the above chart

will

still

provide

a

useful setting guide, however

far

uptimum

results, voltage

adjustment

may

be

nceessary

-

in

general

the

voltage setting

will

need

to

be

r-educcd.

Recammended

gas

flow

rate

for

mixed

gases

is

10

-

15

l

i

Lr-es/mintl-ke.

WELBMATIC UTILITY MANUAL

PAGE

10

PARS

CP33-50

CP1,8"12

cf315-14

cFJ33-0/4

CP29-0/7

CP35,-16

CP15-13/2

CP15-13/3

CP3"9/8

CP15-0/7

CP18-0/8

w1-22

W1-23

CPZ

5-0

/

18

CP25-0/19

CP15-0/14

CP18"14

CPSS-15

CP15-27

CP

3-5-28

WIN44

MC=14-1/14

AM

1

b

08029F

CP18-0/22

CP53-23

WIN122

CPl5-30

DESCRIPTION

BASE

FRAME ASSEMRLY

TRANSFORMER ASSEMBLY

INDUCTRNCE ASSEMBLY

FAN EILADE 250" DIAMETER

FAN

MOTOK

RECTIFIER ASSEMBLY

DIODE

(SEMIKRON

SKR240/04)

DIUDE (SEMIKRON

SKN240/04)

THERMOSTAT

HEATER

PLUG

SOCKET

WELDING CONTACTOR

INDICATOR LIGHT

FUSE

HOLDER

FINE SELECTCIA SWITCH

GOI1RSE

SELECTOR SWITCH

CONT'ROL PLUG

FRONT PANEL

BACK PANEL

TOP

COVER

SIDE PANELS

TYPE

NB./SERIOL

NO.

PLATE

TERMINAL STRIP

QUTPUT TERM

I

NALS

1/2"W.

EYE

NUT

LOOM

ASSEMBLY

AIR

FLOW

FINS

TERMINAL CONNECTION NAMEPL

PIVOT IiOUNTING

FOR

W17

ATE

L

l1

W

c

6

(d

W

c

jk

c

0

00

J

0

c.

1

0

7”

W

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WIA Weldmatic Utility Owner's manual

WIA Weldmatic Utility Owner's manual

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