WIA Weldmatic 250 Owner's manual

WELDMATIC

250

MODEL

NO.

CP25

"""""

CAT.

7523/25

9/80

FROM SERIAL

NO.

2539-'l

THE INFORMATION CONTAINED

IN

THE FOLDER

IS

SET OUT TO ENABLE

YOU

TO PROPERLY MAINTAIN YOUR NEW EQUIPMENT

AND

ENSURE THAT

YOU

OBTAIN

MAXIMUM

OPEFWTING EFFICIENCY.

PLEASE ENSURE THAT THIS FOLDER

IS

KEPT

IN

A

SAFE PLACE FOR

READY REFERENCE WHEN REQUIRED.

WHEN REQUESTING SPARE PARTS, QUOTE THE MODEL

No.

AND

SERIAL

No.

OF

THE MACHINE

AND

THE PART

No.

OF

THE ITEM REQUIRED.

FAILURE

TO

SUPPLY THIS INFORMATION WILL RESULT

IN

UNNECESSARY

DELAYS

IN

SUPPLYING THE CORRECT PARTS.

WELDING INDUSTRIES

OF

AUSTRALIA PTY. LTD.

Melbourne

429 4766

Sydney

534 2144

Newcastle

61 1668

Adelaide

352

3022

Brisbane44

1391

Perth

361 7088

Launceston

317004

Darwin

81 6427

&

84 3076

OPERATING

AND

MAINTENANCE

INSTRUCTIONS

-

WELDMATIC

250 (CP25)

-

INTRODUCTION

GENERAL

This manual has been prepared especially for use in

familiar-

'izing personnel with the design, installation, operation,

maintenance, and troubleshooting of this equipment,

All

information presented herein should be given careful consid-

eration to assure optimum performance of this equipment.

"

RECEIVING/HANDLING.

Prior to installing this equipment, clean

all

packing

material

from around the unit and carefully inspect for any damage that

may have occurred during shipment. Any

claims

for loses or

damage that may have occurred in transit must be

filed

by the

purchaser with Welding Industries of Australia Pty. Ltd.

or

authorised agent immediately (refer to EQUIPMENT

WARRANTY

card

enclosed with Operating Instruction Manual).

When requesting information concerning this equipment,

it

is

essential to supply correct Plodel identification and machine

serial

number.

SAFETY.

Before the equipment

is

put into operation, the SAFETY PRACTICES

section

at

the back

of

this manual MUST

BE

READ

COMPLETELY.

This

will

help avoid possible injury due to misuse or improper

welding applications.

CONTENTS

PAGE

NO.

General Description

1

Setting up for Operation

2-3

Welding Operation Instructions

4

Maintenance Instructions

5

Welding

Data

-

Table

"C"

6

-

Parts

List

CP.25-04 Issue

1

7

-

Assembly Drawing

CP.25-04

Issue

1

8

Circuit

Diagrams

-

CP.25-C5

9

Mobile

Kit

Assembly

-

AM117

Safety

Practices

Guarantee Card

-1-

STANDAXD

UNIT

The

construction

of

the

standard package plant

has

been designed

for installation and operating in

a

wide

variety of applications,

such

as

high production factories and general fabrication shops.

"WELDMATIC"

Plants consist of

three

basic

units:-

1.

Constant Potential

Rectifier

Power Source.

2.

Semi-Automatic

Wire

Feeder.

3. Welding Gun and

Cable

Assembly.

Separate operating and maintenance instructions

are

provided

for

the

wire

feeder

and

gun

cables.

1.

POWER

SOURCE

-

FEATURES

The standard

C.P.

rectifier

power source

is

housed in

a

drip-

proof enclosure. Lifting lugs

are

provided

for

crane trans-

portation. For units

with

wheel

mounting four wheels

are

provided;

the

two

front

wheels

are

steerable

permitting easy

movement in

restricted

floor space.

A

push

bar

is

provided

on

the

front

of

the

machine

and

a

gas

cylinder

carrier

with

a

support

bracket

and chain

at

the

rear.

A

l10

volt plug socket

is

located on the

rear

panel for connection

of

gas preheater

when welding

with

C02

gas

shield. Located

on

the

front panel

are

a

ON/OFF

switch,

coarse

voltage selection switch, fine

voltage selection switch, control fuses,

wire

feeder plug socket

and

rectifier

power outlet sockets.

2.

CONSTRUCTION

The

power source

is

a

Constant Potential Silicon Diode

Rectifier

D.C.

Welder,

with

a

three

phase transformer and

a

three

phase

rectifier

bridge. Connected in

the

output circuit

is

an induc-

tance unit providing

the

"inductance" or degree

of

slope neces-

sary for various welding currents. Cooling of the silicon diodes,

transformer windings and inductance unit

is

by

a

single phase

axial fan. The power source

is

protected against fan failure

and overheating by thermostats mounted on diode

heat

sinks.

3,

WELDING

PROCESS

Gas

metal

arc

welding within

the

capacity

of

the

power source

can

be

carried out

with

the following equipment:-

a)

Semi-automatic

wire

feeder model

W14.

b)

Semi-automatic

wire

feeder

with

spot

timer

W14-20.

c)

"Hobart" spool gun welding unit model

SP9

with

CV2

controller.

d)

"Mini-mig" push and pull gun and control.

4.

WELDING

CAPACITY

Power Source Capacity

is

as

follows:-

250

Amps,

32 volts,

100%

duty cycle.

-

-2-

5.

SUPPLY

AND

WELDING

CABLES.

Power Sources are suitable for connection to

a

415 volt

50

Hertz

3

phase

supply.

The

recommended fuse size, primary cable

size

and welding

cable

size

are

as

follows:-

Fuse

-

15

amp.

Primary Cable

-

4

core 30/0.25

T.R.S.

Welding Cable

-

1121/0.20

T.R.S.

SHIELDING

GASES.

Welding

Grade

C02

for

all

mild

and alloy

steel

welding in

thicknesses ranging from

lmm

upwards.

Argon/C02

or

Argon/Oxygen mixtures for

all

applications on

low currents requiring minimum of spatter on sheet

steel

and

for

stainless

steel

welding.

Argon/Oxygen and Argon/C02 mixtures for prime quality welding

of

stainless

steel.

Argon (pure) for

all

aluminium welding.

SETTING

UP

UNIT

FOR

OPERATION.

-

General

Assembly

of

Packaged Plant

(Refer

Drawing

AM117)

Welding machine

is

shipped

as

a

skid mounted unit.

If

the

machine has been supplied

with

wheels

and

bottle

carrier

they

should

be

fitted

on

the

machine

as

shown on Drawing

AM217.

If

a

"Mini-Boom"

wire

feeder

mounting

is

supplied, locate the

vertical boom post in the special

swivel

mount

at

the

rear

of

the machine. Locate the

"Wire

Feeder"

on

the

swivel

mount,

ensuring that the fibre thrust

washer

is

on

the

pivot pin.

Check

that

the

"Wire

Feeder"

is

free

to swivel in

a11

directions.

If

necessary apply

a

small

amount of

graphite

grease

to

shaft.

b) Connection to Mains Supply.

Note:

This

work should only be

done

by

a

qualitfied

electrician.

The

power source

is

designed for connection to 415 volt,

50

hertz,

3

phase supply and the supply voltage should

be

ascertained before

connecting the machine.

Access

to

supply connection terminals in

machine may be gained by door in right hand

side

panel.

Use

a

flexible

4

core

primary

cable

for

portable machines and clamp

cable

to ensure that

there

is

no strain on

cable

connections.

The

earth

(or ground) connection (green/yellow) must be securely fastened

to

the

'earth' terminal on

the

machine adjacent

to

the supply

connection terminals.

-

CAUTION

Before inserting primary cable plug in mains supply

socket, ensure that

switch

on

both plug socket and welding machine

is

in

'OFF'

position.

-

3-

c) Connection

of

Cables/Hoses, etc,

With

unit

switched

'OFF'

connect control cable

(4

pin plug)

from power source to wire feeder. Connect gas hose from. wire

feeder

to

gas regulator/flowmeter, ensuring all connections

are tightened

firmly.

If

C02

Gas Shield

is

being used, plug

heater into

110

volt socket at rear of

unit.

Next insert gun

cable into socket of wire feeder output guide and retain

in

place

with

set screw provided. Set screw should not be

tightened

so

as to prevent

gun

cable from swivelling. Connect

"Gas Hose" and

"Gun

Switch" leads to respective sockets.

cl)

WELDING

CABLES.

All

G.M.A.

welding

is

done

with

electrode wire connected to

"positive" pole commonly

known

as

D.C.

reverse polarity

(D.C.R.P.)

therefore, connect the short jum.per lead from.

l'+''

socket on machine to terminal lug on gun cable. The work Lead

("negative") should be plugged

into

the

''-It

socket

on

the

machine. The plugs

of

the welding cables

must

be

fully

inserted

in

the sockets,

to

prevent accidental disconnection.

To

avoid

error, welding should not be attempted

until

all connections

have been secured. The wire feeder may be installed remote

from.

the power source,

in

which case, extension lead sets corn-

prising power cable, gas hose and control cable(four core) are

required

in

accordance

with

the desired 1ength.Standard length

available from. stock

is

9

metres.

3)

WIRE

FEEDER

AND

GUN

CABLE.

Fit

a spool

sf

wire to the wire feeder (see notes

in

"Wire

Feeder Instruction Manual")

Tighten the "brake" screw

until

a

slight braking effect

is

felt when turning the wire spool

by

hand to prevent "over-run" when wire feed stops. The wire

drive rolls and inlet wire guide should be selected

in

accord-

ance

with

the diameter and type of wire being used. Refer to

current wire feeder manual for correct selection of wire feed

rolls and input guides.

0.8mm

=

0.030"

0.9mm.

=

0.035"

1.2m

=

0.045"

The gun cable and gun are normally delivered

with

the

contact

tip and liner spring for wire size nominated,

but

check that

both are correct size

for

wire

being used.

i,

i-

-5

L3

-4-

WELDING

OPERATION

INSTRUCTIONS

-

8.

SINGLE

FUNCTION

CHECK

Unit

is

now ready for operation, but prior to commencing weld-

ing, the following "functions check"

is

recommended, switch on

power source and

check

air

flow.

See

that

all

welding lead

plugs

are

inserted in the correct polarity sockets

-

electrode

"positive", work "negative". Check

all

welding connections

and plugs for tightness particularly

"work"

clamp.

Next ensure

that

all

control

cables

and gas hoses

are

securely

connected and

that

Gas

Heater

(for

C02

only)

is

plugged into

socket

at

rear

of

power source. Switch on

wire

feeder, indic-

ator light should now show "Power

On".

Open

Gas

cylinder

fully and check contents gauge for adequate gas supply.

Press

"Gas

Purge" switch and

set

gas

flow in accordance with

welding requirements

,

at

the

same

time

check that gas

flow

is

adequate

from

gun nozzle. Set

"wire

speed" control

to

desired

wire

speed.

Press

"wire

inch" switch and check

wire

feed

for

correct pressure on

drive

rolls. Pressure should be sufficient

to

prevent any ''slip" when feeding through gun and cable.

Next,

close

gun switch momentarily for

wire

feed, gas flow and

welding power check.

Set

the voltage selector switches in

accordance with required voltage

(see

welding

table)

,

unit

is

now ready for welding..

9.

SETTING

OF

WELDING

CURRENT

AND

VOLTAGE

Welding current

is

determined automatically by the

'wire

speed'.

The electrode

wire

is

fed

at

the pre-selected speed by drive

rolls through the gun cable to the

arc

at

a

constant speed,

unchanged except when

reset

by the

'wire

speed' control. The

higher the

wire

speed, the higher the welding current.

The output voltage of the power source when the gun switch

is

closed,

is

divided into

a

number

of

steps by coarse

selector

and fine selector switches. The 'coarse' selector switch works

in conjunction with

a

"fine"

selector

switch giving

30

voltage

steps

.

The

following sequence of

weld

setting

is

recommended:-

a)

Consult typical

weld

setting chart.

b)

Select

welding current most suited

to

the application by

following the settings of

wire

speed and voltage shown on the

setting chart. To "tune" each

weld

setting, adjust

wire

speed

only.

c)

If voltage

is

too low for the application,

wire

"stubbing"

will

occur, particularly

at

start

of weld and

weld

contour

will

be

very convex. If the voltage

is

too high,

metal

transfer

will

be

erratic

with excess spatter,

d)

With welding current and voltage matched the result

will

be

an optimum tuned welding condition with

a

smooth spatter-free

arc.

-

-5-

10.

SAFETY

DEVICES

In

the event of the power source becoming overheated the ther-

mostats on the diode heat

sinks

will

operate preventing further

welding. The thermostats

will

automatically reset and

with

the

cooling fan operating

this

will

take approximately

10

minutes.

A

check should be made to ascertain the reason for the over-

heating such as fan not operating or air flow restricted.

Fuses provided for all circuits are as follows and are indicated

on the front panel:-

Fuse

El

-

3

amps

(Delayed action)

Fuse

E2

-

3

amps

(

Fuse

E3

-

5

amps

(

Fuse

E4

-

5

amps

(

I1

I'

1

I'

)

"

1

11.

MAINTENANCE

a) Power Source

Apart from the fan the rectifier has no rotary components.

To

achieve complete dissipation

of

heat from the active components,

the rectifier should be thoroughly blown off

with

dry

compressed

air after

6

months' operation. Cleaning should be carried out

at shorter intervals if

dust

accumulation

is

considerable.

Prior to cleaning, remove the

unit

cover

by

detachment of lugs

and the fixing screws.

Thus

all

the components of the power

source

will

be accessible.

b)

The wire feed motor/gearbox

is

pre-packed

with

grease and

needs no other lubrication. Change the grease after approximately

14,000

service hours. (see Wire Feeder Instruction Manual).

The drive rollers and the inner wire guides should be kept

clean.

If

necessary, blow off the inside

of

the wire feeder

with

compressed air.

c)

Gun

and Cable

Remove any spatter which

might

adhere to the nozzle bore

so

that the shielding gas outflow

is

not impeded. The condition

of the contact tubes should be regularly checked. Damaged and/

or

burnt

tubes are an impediment to trouble-free welding

operation and should be replaced immediately.

Trouble-free operation depends to

a

large extent

on

the good

condition and cleanliness of the inner wire liner (See Instruc-

tions on

Gun

Cables).

12

.

WELDING

OPERATION

Never observe the arc

with

unprotected eyes.

It

is

of

impsrt-

ance that the welder wear protective clothing providing suffic-

ient safety.

-6-

13.

STOPPAGES

AND

THEIR

ELIMINATION

The machine

should

be checked only

by

a fully skilled electrician.

If the

unit

stops working,

first

determine whether stoppages are

initiated

by

the mains (for instance,

burnt

fuse) or

by

the

supply cable (loose connection, cable break) or by the

unit

proper.

If the three terminals

L1,

L2

and

L3

on

the primary terminal

board are correctly connected

to

the mains (voltmeter reading)

the

cause

of

the stoppage

must

be sought

in

the

unit

itself.

The wiring diagram on the next pages

will

facilitate the location

of the defect.

WELDING

DATA

-

TYPICAL

VALUES

Shielding Gas

is

welding Grade

C02

used

with

a Gas Preheater.

Contact Tip

1.5mrd

inside of Gas Nozzle, Wire "Stick

Outt1

6

-

9m.mup

to

200

amps.

9

-

12mmover 200 amps. These Tables are

a

guide only for initial machine setting and finer adjustments

may be necessary to achieve optimum welding characteristics for

the application. Recommended machine setting method

is

to set

Voltage Switches, Inductance and Gas Flow

as

per Table then

adjust wire speed to obtain recommended current.

0

,

$m-

Wire Speed Volts

Amps

.

l.g(metres/min)

18.0 50

3.0

'I

17.0 75

3.7

18.0 85

4.1

It

19.0

100

5.0

I'

19.5

120

6,8

It

21.5 150

9.2

23.0

175

'2.1

It

25.0

200

-6.8

'I

II

32.0 250

II

I1

l1

I1

II

I1

3,

c

2mm

MILD

STEEL

WIRE

Wire Speed Volts

Amps.

2.5(rnetres/min)

18.0

100

2.9

18.5

130

3.3

19.0

140

4.0

20.0

160

5.3

23.0 200

6.4

23.0 230

8.2

28.0

250

10.8

I1

It

32.0 280

13.4

32.0 300

I1

II

11

II

I1

11

II

I1

It

I1

NOTE:

Wire speed

is

shown

in

metres/minute and are not dial

calibration settings.

-

DRAWING

NO.

CP25-04 ISSUE

NO.l.

7:

-

ITEM

NO.

l

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

-

PART

NO.

CP25-45

CP25-34

CP15-l4

CP29-0/6

CP25-50

CP15-0/7

CP2-0/13

CP3-0/30

CP3-0/35

CP3-0/47

dl-

2 2

Xl-

2

3

=1P29-0/20

2P25-0/18

'

ZP25-04/16

3?15-0/14

3'25-49

3P25-46

c1P35-13

3P35-14/1

31?35-14/2

c1P25-48

UN44

:IC14-1/14

ZP35-18

U41

6

L0029F

DESCRIPTION

BASE FKAME ASSEMBLY

TRANSFORT.IER ASSEL-BLY

INDUCTANCE ASSEE43LY

FAN

BLADE

FAN

MOTOR

RECTIFIER ASSEMBLY

GAS

HEATER PLUG

WELDING CONTACTOR

AI,V.IF:TER SHUNT 0-400A.

AllPlETER 0-400A

VOLTMETER

0-6011.

INDICATOR LIGHT

FUSE HOLDER

OFF/ON

SWITCH

FINE SELECTOR SWITCH

COARSE SELECTOR SWITCH

CONTROL PLUG

FRONT PANEL

BACK

PANEL

TOP COVER

LEFT

HAND

SIDE COVER

RIGHT

HAND

SIDE COVER

CONTACTOR

&

SWITCH BAFFLE PLATE

TYPE NO./SERIAL

NO.

PLATE

TERMINAL

STRIP

TIE

BAR

OUTPUT TERMINALS

EYE NUT

8

n

I

\

0-

B-

I

l-

0

m

cu

@l

l

I

"Q

I

r

a

n

I-"

1:

I

l

I

l

I

l'

-L1

I

4

IN

.m

J

TI

m

l

0

C

WELDMATIC

250

MODEL NO. CP25

”””””

CAT.

7523/25

5/79

THE INFORMATION CONTAINED IN THE FOLDER

IS

SET

OUT

TO ENABLE

YOU TO PROPERLY MAINTAIN YOUR NEW EQUIPMENT AND ENSURE THAT

YOU OBTAIN MAXIMUM OPERATING EFFICIENCY.

PLEASE ENSURE THAT THIS FOLDER

IS

KEPT IN A SAFE PLACE FOR

READY REFERENCE WHEN REQUIRED.

WHEN REQUESTING §PARE PARTS, QUOTE THE MODEL No. AND SERIAL

No. OF THE MACHINE AND THE PART

No.

OF THE

ITEM

REQUIRED.

FAILURE TO SUPPLY THIS INFORMATION

WILL

RESULT IN UNNECESSARY

DELAYS IN SUPPLYING THE CORRECT PARTS.

EELDING INDUSTRIES

OF

AUSTRALIA PTY. LTD.

Melbourne

465 2511

Sydney

534 2144

Newcastle

61 1668

Adelaide

352 3022 Brisbane44 1391

Perth

361 7088

Hobart

34

7850

Darwin

81

6427

&

84 3076

OPERATING

AND

MAINTENANCE

INSTRUCTIONS

WELDMATIC

250 (CP25)

INTRODUCTION

GENERAL

This manual has been

prepared

especially

for

use in

familiar-

izing personnel with the design, installation, operation,

maintenance, and troubleshooting

of

this equipment.

All

information presented herein should

be

given careful consid-

eration

to

assure optimum performance

of

this equipment.

RECEIVING/HANDLIN~.

Prior

to

installing this equipment, clean

all

packing

material

from

around

the

unit and carefully inspect

for

any

damage

that

may have occurred during shipment. Any

claims

for

loses

or

damage

that

may have occured in transit m.ust

be

filed

by

the

purchaser

with

Welding Industries

of

Australia

Pty.

Ltd.

or

authorised agent

immediately

(refer

to

EQUIPMENT

WARRANTY

card

enclosed with Operating Instruction Manual).

When requesting information concerning

this

equipment,

it

is

essential

to

supply

correct

Model

identification and machine

serial

number.

SAFETY

e

Before

the equipment

is

put into operation,

the

SAFETY

PRACTICES

section

at

the

back

of

this

manual

MUST

BE

READ

COMPLETELY.

This

will

help

avoid

possible

injury due

to

misuse

or

improper

welding applications.

CONTENT

S

PAGE

NO.

General Description

1

Setting up

for

Operation

2-3

Welding Operation Instructions

4

Maintenance

Instructions

5

Welding

Data

-

Table

"C"

6

-

Parts

List

CP.

25-01

Issue

2

7

-

Assembly Drawing

CP.

25-01 Issue

2

8

Circuit Diagrams

-

CP.25-C

3

9

Mobile

Kit

Assembly

-

AM51

Safety

Practices

Guarantee Card

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

PART

NO.

CP35-l1

CP25-11

CP25-16

CP24-0/4

CP24-0/5

CP3-9

CP25-0/7

CP2-0/9

CP3-62

CP2-0/13

CP3-0/30

CP3-0/35

CP3-0/44

w1-

2 2

1071-

2

3

CP25-0/18

C225-0/19

CP2-0/31

CP25-19

CP35-12

CP35-13

CP35-14/1

CP35-14/2

CP35-15

WIN

4

CP35-17

AM1

6

CP25-26

CP35-18

CP35-19

10029F

TC262

TC262N

1030010

MC40-20/3

Cl?35-0/37

CP35-0/38

7

DRAWING

NO.

CP25-01

ISSUE

NO.

2

DESCRIPTION

Frame Assembly

Transformer

Assembly

Inductance Assembly

Fan Blade

Fan Motor

Rectifier

Assembly

Control

Transformer

Gas

Heater

Plug

Rectifier

Protection Assembly

Welding

Contactor

Ammeter

Shunt

Ammeter

0-400

Amps

Voltmeter

0

-

60

Volt

Indicator Light

Fuse Holders

Fine Selector Switch

Coarse

Selector Switch

Control Plug

Front

Panel

Back Panel

Top

Cover

Left

Hand Side

Cover

Right Hand Side

Cover

Contactor and Switch Baffle

Plate

Type

No.

Serial

No.

Plate

Terminal

Assembly

Output

Terminals

Transformer Support

Tie

Bar

Fan Mounting Bracket

Eye Nut

Gas

Outlet

Fitting

Nut

f

or

Above

3/4"W

x

3" Hex.

HD.

Set Screw.

Bakelite Insulators

Loom

Assembly

Zas

Hose

I.

~W

b

J

0

N

U

d

@-

I

"I

"-@

nnn

ti

P

i"

W

rl

l

_____

______".___________

J

a

5.

-

SUPPLY

AND WELDING

CABLES.

Power

Sources

are

suitable for connection

to

a

415

volt 50

Hertz

3

phase supply.

The recommended fuse size, primary

cable

size and welding

cable

size

are

as

follows:-

a)

Fuse

-

15

amp.

b)

Primary

Cable

-

4

core

30/0.25

T.R.S.

c)

Welding

Cable

-

1121/0.20

T.R.S.

6.

SHIELDING

GASES.

a)

Welding Grade

C02

for

all

mild

and alloy

steel

welding

in

b)

Argon/CO2

or

Argon/Oxygen mixtures

for

ab1

applications

on

thicknesses ranging from

lmm

upwards.

low

currents requiring minimum

of

spatter

on sheet

steel

and

for

stainless

steel

welding.

of

stainless

steel,

c)

Argon/Oxygen

and

Argon/C02

mixtures

for

prime

quality welding

d)

Argon (pure) for

all

aluminium welding.

7.

SmTING

UP

UNIT

FOR

OPERATION.

a)

General

Assembly

of

Packaqed Plant

(Refer

Drawing AM511

The

Rectifier

Welder

is

shipped with the skids

or

wheels unbolted.

Bolt

on

the

wheel

assemblies

with

the

steerable

(swivel) wheels

nearest the front panel and push

bar.

If

a

"Mini-Boom."

wire

feeder mounting

is

supplied,

locate

the vertical boom post in

the

special

swivel mount

at

the

rear

of the machine.

Locate

the

Wire

Feeder

on the

swivel

mount, ensuring

that

the

fibre

thrust

washer

is

on

the

pivot pin.

Check

that

the

"Wire

Feeder"

is

free

to

swivel in

all

directions.

If

necessary apply

a

small

amount

of

graphite

grease

to

shaft.

-

b)

Connection

to

Mains Supply.

Note:

This work should only

be

done

by

a

qualified electrician.

The

power

source

is

designed

for

connection

to

415

volt,

50

hertz,

3

phase supply and the supply voltage should

be

ascert-

ained

before

connecting

the

machine.

Access

to

supply connec-

tion

terminals in machine may

be

gained by

door

in

right

hand

side

panel.

Use

a

flexible

4

core primary cable

for

portable

machines and clamp

cable

to

ensure that there

is

no

strain on

cable

connections. The

earth

(or

groud) connection (green/

yellow)

must

be

securely fastened

to

the 'earth' terminal on

the machine adjacent

to

the,supply connection terminals.

"

CAUTION

Before

inserting prim.ary

cable

plug in mains supply

socket,

ensure that

switch

on both

plug

socket

and welding

machine

is

in

'OFF'

position.

-

1.

-

STANDARD

UNIT

The

construction

of

the

standard package plant

has

been designed

for installation

and

operating in

a

wide

variety

of

applications,

such

as

high production factories and general fabrication shops.

"V!ELDE.WTI:C"

Plants consist

of

three

basic

units:-

l.

Constant Potential Rectifier Power Source.

2.

Semi-Automatic

Wire

Feeder.

3.

Welding Gun and Cable Assembly.

Separate

operating and maintenance instructions

are

provided

for

the

wire

feeder

and gun cables.

l.

POWER

SOURCE

-

FEATURES

The standard

C.P.

rectifier

power source

is

housed in

a

drip-

proof enclosure, Lifting lugs

are

provided

for

crane trans-

portation.

For

units with wheel mounting four wheels

are

provided; the two front wheels

are

steerable

permitting easy

movement in

restricted

floor space.

A

push

bar

is

provided

on

the

front

of

the

machine and

a

gas cylinder

carrier

with

a

support

bracket

and chain

at

the

rear.

A

110

volt plug

socket

is

located on the

rear

panel for connection of gas preheater

when welding

with

C02

gas shield. Located

on

the

front panel

are

a

ON/OFF

switch,

coarse voltage selection switch, fine

voltage selection

switch,

control fuses,

wire

feeder plug

socket

and

rectifier

power outlet sockets.

2.

CONSTRUCTION

The

power source

is

a

Constant Potential Silicon Diode

Rectifier

D.C.

Welder,

with

a

three

phase transformer and

a

three

phase

rectifier

bridge. Connected in

the

output circuit

is

an induc-

tance

unit providing the "inductance" or degree

of

slope neces-

sary for various welding currents. Cooling of the silicon diodes,

transformer windings and inductance unit

is

by

a

single phase

axial fan. The power source

is

protected against fan failure

and

overheating by

thermostats

mounted on diode heat sinxs.

3.

WELDING

PROCESS

Gas

metal

arc

welding within

the

capacity of

the

power source

can

be

carried out

with

the

following equipment:-

a)

Semi-automatic

wire

feeder

model

W14.

b)

Semi-automatic

wire

feeder

with spot

timer

W14-20.

c)

"Hobart"

spool

gun welding unit model

SP9

with

CV2

controller.

d)

"Plini-mig" push and pull gun and control.

4.

WELDING

CAPACITY

Power: Source Capacity

is

as

follows:-

250

Amps,

32

volts,

100%

duty cycle.

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WIA Weldmatic 250 Owner's manual

WIA Weldmatic 250 Owner's manual

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