WIA Constructor 500 Owner's manual

I-

CONSTRUCTOR

5

O

MODEL

MC56

A.C.-.D.C.-H.l?.

""""""

CAT.

7505

2/79

THE

INPORMATION CONY'AIDIEL) IN

THE

FOLDER

IS

SET

OUT

TO

ENABLE

'YOU'

TO

PROPERLY

MAINTAIN

YOUR

NEW

EQUIPMENT

AND

ENSURE

THAT

YOU

OBTAIN

MAXIMIJM OPERATING

EFFICIENCY.

PLEASE

ENSURE

THAT

THIS

POLDER

IS

KEPT

IN

A

SAFE PLACE

FOR

READY REFERENCE

WHEN

REQUIRED.

WHEN

FEQUESTING

SPARE

PARTS,

QUOTE

THE

MODEL

NO.

AND

SERIAL

NO.

OF

THE

MACHINE AND

THE

PART

NO.

OF

THE

Ir.['Ebl

REQUIRED. FAILURE

TO

SUPPLY

THIS

INPORbIATZON

WILLl

NESULT

IN

UNNECESSARY DELAYS

IN

SUPPLYING

THE:

CORRECT

PARTS.

WELDING INDUSTRIES

OF

AUSTRALIA

PTY.

LTD.

SAL,ES

AND

SERVICE

DIVISIONS.

Melbourne

465

2511

Sydney

534

2144

Newcastle

61

L668

Adelaide

352

3022

Perth

361

7088

Brisbane

44

1391-

"""""""L-

swm

AGENTS

I_-lp"-l

Launceston

317

004

Darwin

81

6428

&

84

3076

This nanual

has

been

p-epzred

especially

for

use

in

farnili.ir-

izing :xrsc?nnel

with

the

design,

installation,

operation,

main-

tenance

I

and troubl.eshooting

of

this equipment.

All

informa-

tion presented herein should

be

given careful consideration

to

assure

opkimum

performance

of

-?.his

cqdiprnent-..

When requesting inforxation concerning this

eyuiplcen

t:,

it

is

essential to supply correct

Model

identification and Machin2

Serial

No.

I

I.

Page

Specicications

Installation

Operation

Maintcnamce

-

Model

MC55

Maintenance

I-

Model

MC55/J.

Parts

List

-

MC55-0,

Issue

No.3.

Assembly

Drawing

No

-

I4C55-0

Parts

List

-

MC55-66,

Issue

No.1

Traasformer

Drawing

No.

MC55-G6

SAFETY

PRACTICES

Appendix.

for

Model

MC56,

A.C.-D.C.-H.P.

E

1

2

2&3

4

5

OPERATZFG

AND

MAINTENANCE

"

INSTRUCTIONS

W.I.A.

"CONSTRUCTOR

-500"

I

~ ~

""

~__

""-

.l

HEAVY

DUTY.

A.

C,

ARC

WELDER

"""-.""I."

l"__

,___lp"-llllll

I

"L."-~"-^"--

SPECIFICATIONS

-

MODEL

MC55

:-

MANlJAL

CURRENT

CONTROL.

l

I

MODEL

MC55/1:-

ELECTRIC

CURRENT

CONTROL

WITH

REMO'I'E

CONTROL

PROBE.

I

l

PRIMARY

DEMAND:

77

AMPS.

POWER

SUPPLY:

415

VOLT,

50

HZ,

SINGLE PIIASE

A.C.

l

OPEN

CIRCUIT

OUTPUT VOLTAGE:

75

VOLTS.

WELDING

CURiXEWT

PJWGE:

90

-

500

AMPS.

DUTY

CYCLE

:

100%

AT

470

rzMPS/38

VOLTS

60%

AT

500

AMPS/40

VOLTS

"

INST'ALLATION

PRIMARY WIRING

The

Power

Source

is

designed

to

operate

from

a

single

phase,

415

volt,

50Hz.

supply. The primary connection must

be

made

by

qualified

electrical

personnel who

will

erlsure

that

the

installation

satisfies

the

requirements

of

the Power Supply Aut1lorif;ies.

The

primary terminals

are

mounted on

a

terminal board located

at

the

rear

sf

the

machine, behind

the

terminal

access

cover, and

are

marked

L1

and

L2.

The

mains earth terrninal

is

clearly labelled

a.nd

must

be connected

at

all

times

t.o

the

earthing

system.

Note:

High primary current surge

can

occur on striking

th.e

arc,

and during welding,

and

for

this

reason,

IIRC

fuses

should

be

avoided.

When

HRC

fuses

are

used,

consideration

of

the

above

is

advisable

when

selecting the

fuse

rating.

SITE

The

Welding

Power

Source

is

dependent on natural convection

cooling

drawing

air

in

from

the

base

of

the machine, therefore

it

is

essential

that

it

be

installed in

an

area

where

there

is

no

obstruction

to

the

free

circulation

of

a-ir, ensuring adequate

ventilation to

the

machine.

"I

DO

NOT

install

under

work

benches

or

shelving

and keep

a.ir

ducts

clear

at

all

times.

DO

NOT

place

articles

on

top

of

the machine.

WELDING

LEADS

Electrode and

work

leads

should

be

selected

to

suit

the

welding

application and

duty

cycle

as

follows:

'"

L

"

300

amps.

60%

-

use

50mm2

703/0.30

Copper Neoprene

Welding

Cable.

4.00

amps.

60%

-

use

70mm"

988/0.30

l'

It

fl

500

amps.

60%

-

use

951ru-n~

1332/0.30

I'

~

It

Connect the work

and

electrode leads

to

the marked output

sockets

located

on

tne

front

panel

of

the machine. The welding

current,

as

shown by the indicator on the front panel, can

)?e

adjusted by rotating the current control handle. For

the

Model

MCSS/L

model, current adjustment

is

made

by

pressing either the

increase

or

decrease

button

on

the

remote

controller

or

by

rest-

ing the

remote

current probe contact on the work piece and

making

contact with

the

electrode

holder

at.

.the

opposite

end.

Adjust

the

current

to

suit the type

of

ef.ectrode

in

use,

turn

the

Inachine

ON

and

you.

are

ready

to

coIrtmence

welding.

""~_

I_.

"_ll_

I_

NOTES

APPLICABLE

ONLY

TO

'YHE

MODEL

NC55/1.~

"-___~

-

'This

model.

of

the

"COMSTRUCrTOR

500*

has

been factory fitted

with

a

National

"Weltron"

YC-504R

Remote

Current Controller.

OPERATION

Local

control

of

the welding current

is

achieved

by

pressing the

appropriate Increase/Decrease button on t.he front

of

the

ttWeltroll""control.!.er.

Remote

c.mt.rol

is

achieved by the use

of

the

control. probe.

To

increase welding current,

clip

4-

end

of

probe into the

elec-

trode holder, and

short:

the

-

end

.to

the work.

TIE

longer

contact

is

maintained, the greater

will.

be the change in current

to

DECREASE

welding current, clip

-

end

of

the probe into

elect-

rode

holder and

short

-t

end

to

work.

"-

""

DUTY

CYCLE.

~uty

cycle

is

the pcrcentaqe

of

a

five minute

time

period

that

2.-

the

welding machine

can

be-safely

operated

at

a

given

0utpu.t

current.

Hence,

when operating

at

60%

duty cycle conditions,

(500

amps.

-

40

vo1t.s)

the

machine

arc

time

should not exceed

3

minutes

out

of

every

5

minute period.

This

ti.me

,

however

is

usually accumulat,ed duming pauses

when

changing electrodes and arranging

the

wosk.pi.ece

etc.

-

100%

duty cycle

(380

amps.

-

38

vel-ts)

means t.hat

the

machine may

he

run

continuously under

the

spectf'ied conditions.

"

0pera.kiing

-

""""-

a

welding machine

above

""_

.the

-

duty

".

cycle

conditions

will

resu1.t in

it

overheating and render

the

warranty void.

"~

I"~

_I

I_."

__

L_xI

SECTTON

2

Page

"3

of

3.

The

model

MC55

i.s

bas.ical.ly

a

static

transormer, current

adjustment being obtained

h17

moving

a

steel

shunt

in

and

out

of

the

magnetic

circuit.

Wear

can

occur

on

the guide

rai.1-s

and

lead

screw

which

support

the

shu.nt.

These

cornpcments

should

be

cleaned by

blowing

the

comp1e.k machine

out

with

dry

air,

and

guide

rails

and

lead

screw

lubricated

with

CastroL

type

Blil

grease

once

every

six months.

The

fol.l.owing table

should

be

used

as

a

guide

if

the

Weltron

control'ler

fails

-to

operate

correct]-y.

ails

to operate

(1)

lroo

low

voltage.

(l)

Correct

power

even

with

push

(less

tha.11

170V)

su.ppl.y

.

operating unit

''ON"

(2)

Rlown-off

fuse.

(2)

Repl.ace fuse

(5)

controller

or

on

power source.

l*

!Jutton and

either

in

(3)

Faul.ty' printed

(3)

Replace.

circuit.

(i-)

Improper polarity

of

c:onnect.ing

(3)

Faulty

short-

circuiting probe

(4)

F'aulty signal

detector

or

ita

improper connec-

tion.

Circuit

(5)

Faulty printed

(.l)

Correct

connec-

tiny according

tc

instructions

in

2

-

3.

(2)

IJse

vo1:i"ge

reducing device

presenting

15V

CT

move

of

no-load

voltage

e

(4V

or

move

for

YC-502RST)

(3)

Replace

(4)

Check signal

detector

connec-

tion,

01:

replace.

(

5)

ReFlace

Motor runs once

(I)

Vaulty push

(I)

Replace

switch

power

supply

is

button switch.

3.

t;

e

-L

I'

ON

I'

(2)

Faulty

or

improp-

(2)

Recheck

or

erly

connected

replace

signal

signal detector.

detector.

(3)

Fau.lty

printed

(3)

Replace.

circuri-t

a

4.

Frequently blown-

(l)

Over-loading

(1)

Clean

slide

of

off

fuse

(2)

Improperly

welder

trans-

f

o

rnw

r

.

adjusted

cam.

(2)

Readjust

cam.

""

_____"

J

ITEM

N

1

2

3

4

5

6

7

8

9

10

11

12

13

l4

15

E6

17

18

19

20

21

22

23

21

24.1

25

26

v

PART

NO.

"m

MC5.5-36

MC55-G6

MC55-29

MC55-39

MC55-

3

8

MC55-15

CP24-17

MC55-24

MC55-18

MC55-30

MC55-0/11

MC55-31

MC55-0/13

MC55--0/1.4

AM16

MC55-21

MC55-0/17

MC55-0/18

MC55-28

*

MC35-42

CP3-0/23

MC35-0/10

MC55-32

,

h*

08029F

09050

WIN

44

MC55-0/26

"P,

"_S

DESCRIPTION

""""P

"."X

BASE

FRAPU

ASSEMBLY

T'RANSFORMER ASSEMBLY

FRONT

PANEL

CASE

.

TOP

COVER

ISOLATING SWITCH MOUNTING PLATE

LIFTING

BOLT

TERMINAL PANEL SUPPORT BRACKET

TERMINAL CONNECTION PANEL

INDICATOR

TENSION

SPRING

INDICATOR

TAPE

INDICATOI?

TAPE

CAPSTAN

CLEAR PERSPEX

ISOLATING

SWITCH

OUTPUT

TERMINALS

CURRENT

ADJUSTING

HANDLE

RUBBER

PLUGS

REMOTE CONTROL ASSEMRLY

,

REMOTE CONTROL

DRIVE

COU33EING

FUSE

HOLDERS

RUBBER

GROMME'J!

INDICATOR LIGHT RED

415V.

TOP

BAFFLE

"HARDIFLEX"

EYE

NUT

FIBm

WASHER

SERTAL/TYPE NO NAMEPLATE

SHOULDER

SCREW

DRAWING

N"MC55

-Q

ISSUE

NO3

J

L

I

0

L

1

DRAWING No.

MC:55-66

SPARE

PARTS

LIST

ISSIJE

No.1

"_""_~"_I_

il-

PART

NO:

MC55-69

MC55-70

MC55-50/1

MC55-50/2

MC55-21

MC

5

-

7

5

MC55-1.9

AM74-.1.'7/lO

MC55-61

MCS5-56/1

P4C55"6/2

e-

"_">

""""P.

Y

DESCRIPTION

.

"

M_I

PRIMARY

COIL

ASSEMBLY

SECONDARY

COIL

ASSEMBLY

INSULATING

BUSK

INSULATING WASHER

GU~E

mIr,s

LEAD

SCRET4

BEARING

BLOCK

LEAD

SCH3W

WAVE

WAS

HE

R

GUIDE

RAIL

PRESSURE

PLATE

OUTER

COfiPIU3SSION

SI?RING

INNER

COMPRESSION

SPRING

-FRONT

VIEW

-

SHUNT

&

GUIDE

RAIL

ASSEMBLY

BACK

VIEW

-

iSSUE

N"1

APPENDIX FOR CONSTRUCTOR

500

MODEL

MC56

Model

MCSG

Constructor

500

is

a

500

Amp

60%

Duty

Cycle

A.C.-D.C.-Hiah Fresuencv welding power source. The

machine has internal high current, fan

cooled

rectifier

diodes

and

.high frequency

(H.F.)

generator,

In

addition

a

welding inductance ensures optimum welding characteristic

in

the

B.

C

mode.

FRONT PANEL

CONTROLS

l)

Input

Contactor

Control..

Mains

power

is

connected

to

the

weldxng transformer and the diode cooling fan when the

green push button

is

pressed. The 'power

on'

indicator

should

then

light.

To

de-energise the

unit

press

.red

push-

bu.l;ton

*

~,-.

"---""""-.l~.-..I...I_~

2)

".

High

Frequency

.".

Swi.tch.

-.

The

internal

H.F.

generator

is

con-

tro.EEed

by

a

separate switch

D

Note

that

the

input contac-

tor must be energised

for

the

H.

F. generator

to

operate.

The

H.F.

indicator ].amp should

be

].it

when the

H.F.

unit

is

energised. The brilliance

of

this

lamp

is

a

measure

of

the

spark

intensity. The

H.F.

generator input

is

protected

by

a

I

Amp

fuse.

In

the

event

of

a

failure,

replace

on:Ly

with

a

fuse

of

the

same

rating.

OPE?JiT.'ION

MODES

The

Con

S

truc-tor

welding

modes

~

"

""_.""..I.."."

500

MC56

may

be

connected

to

operate

in

six

he

connection instruct.ions

are

as

follows:

Connect work

lead

to 'Work

A.

C.

terminal.

r:onnect

Electrode

lead

to

'ELECTRODE

A.C.

'

terminal.

A.

C

a

1-17:

GI3

FREQIIENCY

~

_l_ll_

Cannect Work

lead

to

'Work

A.C.

terminal.

Connect

'H.F.

CONNECTOR'

lead

to

'ELECTRODE

A.C.

'terminal.

Connect Electrode lead

to

'H.F.

ELECTRODE'

terminal.

D.

C.

ELECTRODE

POSITIVE

Connect

rectifier

input

leads

to

A.C.

terminals.

Connect

work

lead

to

'D.C.

-'

terminal.

Connect

El,:.ctxode

lead

to

'DC

+'

terminal.

I

-~-

DX.

ELECTRODE

POSITIVE

mG1.1

FREQUENCY

I

Connect

rectifier

input. leads

to

A.C.

terminals.

Connect

Work

I-ead

to

'

D.

C

D

--

'

t.erm:hal

Connect

'H.

F.

CONNECTOR'

lead

to

'D.

C.

-t

terminal.

Connect

Electrode

lead

to

'H.

F.

ELECTRODE

'

terminal..

I).

C.

ELECTRODE

NEGATI:VE

ConQect.

rectifier

input

leads

to

A.C.

terminals.

Corinect

Work

lead

to

D.

C.

+-l

terminal.

Connect Electrode

lead

to

'D.C.-'

terminal.

D.C. ELECTRODE NEGATIVE

&

HIGH

FJXEQUENCY

Connect rectifier input

1.ea.d~

to

A.C.

terminals.

Connect work lead to

!

L).

C.

f

'

terminal.

Connect

'H.F.

CONNECTOR"

lead

to

'D.C.

-I

terminal.

Connect

Electrode

lead

.t.o

H

I:

ELECTRODE

'

terminal.

HEGIf

FmQUENCY

UNIT

The internal high frequency generator contains

two

adjustable tungsten spark

gaps

which

are

factory

set

at

.010"

-

S

015".

~

After

a

period

of

time,

i-t

is

normal that the tungsten

tips

will

become

eroded,

which

will

affect the efficiency

of the generator. Should this occur,

reset

the

gaps

to

the

recommended figure

above.

To

obtain

access

to

the

spark

gap

assembly,

the

machine

top

cover lilust

be

removed,

CONSTRUCTOR

50

0

MODEL

MC56

II

l

TRANSFORMER

WITH

FAN

"

--

,

-.

c

L.."_

WIA Constructor 500 Owner's manual

WIA Constructor 500 Owner's manual

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