WIA Weldmatic 41 Wirefeeder Owner's manual

WELDING INDUSTRIES

OF

AUSTRALIA

A

DIVISION

OF

WELDING INDUSTRIES LTD

ACN

004

547

l

Head

Office

and International Sales

5

Allan

Street,

Melrose

Park

South

Australia,

5039

Telephone

(08) 8276

6494

Facsimile

(08)

8276 6327

INSTALLATION INSTRUCTIONS

PUSHlPULL CONVERSION

KIT

TO SUIT

W41

SERIES WIREFEEDERS

MODEL

NO.

AM287-0, REV.

B

09/99

QUALiTY WELDING PRODUCTS, SYSTEMS AND SERVICE

4

y/t

Page

2

PUSH/PULL

KIT

FOR

W41-SERIES

WIREFEEDERS

CONTENTS

Section Page

1

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

Introduction

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

P.2

2.

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

Receiving

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

P-2

3...

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

Instal lation,,

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

P.

3

4..

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

Operation

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

P.4

5.

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

Parts List

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

P.

5

Figure Page

1

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

W41 -1 Wirefeeder with AM287-0 Kit Fitted

..

.p.5

2

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

AM287-1

l

Push/Pull Control

PCB

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

P.6

3..

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

AM287-0 Circuit Diagram

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

P.

7

4

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

AM287-0 Wiring Loom Details

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

P.8

5

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

Drilling Template

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

P*

9

1.

INTRODUCTION

This conversion kit is intended for fitting

to

W41-0, Enclosed Wirefeeder

-

2

Roll

Drive, or

W41-l, Enclosed Wirefeeder

-

4

Rolt

Drive.

Installation of this kit will enable the operator to use

a

Pull

Welding Gun with the

existing power source and minimum changes to the wirefeeder.

2.

RECEIVING

Check the equipment received against the shipping invoice to ensure shipment is

complete and undamaged. If any damage has occurred in transit, please immediately

notify your supplier.

The AM287-0 Conversion Kit contains;

PCB

Assembly.

Replacement Front Panel.

fitted with;

Inch/Purge Switch.

10

pin Pull Gun socket and attached loom.

Interconnecting Looms.

Installation Hardware.

(This) Owners Manual.

PUSH/PULL

KIT

FOR W41-SERIES WIREFEEDERS

Page

3

3.

INSTALLATION

1.

Remove door and side cover assembly from wirefeeder case.

2.

Remove existing controls from front panel.

3.

Remove front panel.

4.

Fit new front panel (complete with Inch/Purge Switch, 10

socket and attached

loom).

If

converting a W41-0 Wirefeeder

-

2 Roll Drive.

A.

Refit Wirespeed Potentiometer and Knob

B.

Refit Power On Indicator.

C.

Discard Interval and Spot Time Potentiometers and Knobs and attached loom.

If converting a W4l-l Wirefeeder

-

4 Roll Drive.

A.

Refit Wirespeed Potentiometer and Knob

B.

Refit Power On Indicator.

C.

Discard Inch

/

Purge Switch and attached loom.

mount PCB.

5.

Using the paper drill template supplied (See page

g),

drill four holes, 4mm dia.

to

6.

Mount PCB using screws and standoffs supplied.

7.

With reference to Circuit Diagram (See page 7), complete the following wiring

modifications.

A.

Unplug existing loom from socket

PI

on W41-10 PCB and transfer it to socket

P7 on AM2874 1 PCB.

Note. Fit

3

wires from inchlpurge switch into plug P7. White to pin8, Grey

B.

Fit Extension

loom,

Part

No.

AM287-21

,

between P1 on W41 -1

0

PCB and P8 on

C.

Unplug existing loom from socket P2 on W41-IO PCB and transfer it to socket

D.

Fit Extension loom, Part

No.

AM287-22, between P2 on W41

-I

0

PCB and PI

2

E.

Connect two yellow wires from rear of inchjpurge switch to P14 and

P15

on

F.

Connect two black wires from rear of

10

pin socket

to

pins

1

and 4 of existing

G.

Connect plug with blue and orange wires from rear of

4

0

pin socket to P1

3

on

H.

Connect red wire from rear of

10

pin socket to pin P9 on AM287-l 1 PCB.

1.

Connect grey wire from rear of

10

pin socket to pin PI

0

on AM287-11 PCB.

J.

Disconnect in-line connector

in

blue wire from control lead. Connect blue wire

from control lead to P1 on AM287-1 1 PCB. Use Blue wire (part of AM287-23

Loom) to connect blue wire from P4, pin7 on W4140 PCB to P2 on AM287-1

l

PCB

wire from control lead to P3 on AM287-11 PCB. Use Brown wire (part

of

AM287-

to pin7, Black to pin

6.

AM287-11 PCB,

PI

l

on

AM287-l1 PCB.

on AM287-1

-l

PCB.

AM287-11 PCB.

gun switch plug (now connected to PI

l

on AM287-11 PCB).

AM287-11 PCB.

K.

Disconnect in-line connector

in

brown wire from control

lead.

Connect brown

L

Page

4

PUSHIPULL

KIT

FOR

W41-SERIES

WIREFEEDERS

23 Loom) to connect brown wire from P4, pin1 on W41-10 PCB to P4 on

AM287-1

l

PCB

L.

Disconnect in-line connector in grey wire from control lead. Connect grey wire

from control lead to

P6

on AM287-11 PCB. Use Grey wire (part of AM287-23

Loom)

to connect grey wire from P4, pin8 on W41 -1

0

PCB to

P5

on AM287-11

PCB

8.

Refit door and side cover assembly to wirefeeder.

4.

OPERATION

l.

Connect control cable and weld lead from wirefeeder to power source.

2.

Connect gas hoses and use Purge switch to purge gas lines.

3.

Fit selected Pull gun and cable to Euro Connector on front panel of Wirefeeder.

4.

Fit wire spool and use Inch switch

to

feed wire through gun cable.

5.

Set Local/Remote switch,

S1

on AM287-11 PCB, to appropriate position to select

between wirespeed control from wirefeeder (Local) and wirespeed control from Pull

Gun, (Remote). Switch is accessible from spool side of wirefeeder.

6.

Machine and wirefeeder are now ready for welding.

7. Use

FASTELOW

switch in FAST position when wire speed

is

greater than

5.0.

Use SLOW position when wire speed is

less

than

5.0.

PUSH/PULL

KIT

FOR W41-SERIES WIREFEEDERS

Page

5

5.

PARTS

LIST

AM287-0

PUSHlPULL

CONVERStON KIT

FOR

W41 SERIES WIREFEEDER

ITEM

#

PART

#

DESCRIPTION

1

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

AM287-1

l

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

PCB Assembly PushlPull Control

2

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

AM287-20

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

Front Panel W41 PushlPull conversion

3

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

K42

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

Switch Inch/Purge

4..

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

AM287-21

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

Extension

Loom

5

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

AM287-22

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

Gun

Switch Extension

Loom

6

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

AM287-23

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

Power

Loom

7

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

AM287-24

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

Gun Control

Loom

7.

l

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

K57

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

Socket 10 Pin

Includes

8

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

CPIOZ-0/18

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

PCB

Support

(4)

9

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

SSPGGS12P

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

Screw PCB

Fixing

(4)

IO..

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

AB4-6

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

Rivet (4)

FIGURE

l.

W41-1

WIREFEEDER WITH

AM287-0

KIT FITTED.

Page

6

PUSH/PULL

KIT

FOR W41-SERIES WIREFEEDERS

L

l-

0

a

2

U

a

1

r

I

l-

0

a

.-l

0

cc

t-

z

8

U

O

W

a

m

l

II

I

l

.I;

I

5

I

z

S

3

FIGURE

2.

AM287-I1

PUSHIPULL CONTROL PCB

l

PUSH/PULL

KIT

FOR

W4f-SERIES WIREFEEDERS

Page

7

"l

n

W

PIX

v)-

t.

0

0.

z

W

a

v)

5

W

"_"

r

m

.-l

"_

l

I

A

I-

I

-L

I

_I

-

"_

I

l

I

l

I

v)

c

L

W

L

0

D.

z

0

V

lx

W

L*

W

E

3

Lo

z

t-.

v)

X

W

n

Y

,4

1

l

I

J

II

.""""""""_A

W

r---

I

j

"dq

,

u-l

'

orn

,

n1q

I

hJ6

I

I I

l

I

l"-I

0

V

d

..

c1

I.,

e

"-

4

PIN AMP PLUG

4

PIN AMP PLUG

PART NO.

K354

PART NO.

K354

Page

8

PUSH/PULL

KIT

FOR

W47-SERIES WIREFEEDERS

8

PIN AMP PLUG 8 PIN AMP PLUG

PART

NO.

K35-8

ION

I

OOM. PART

NO.

AM787-21

4

PART

LONG INSULATOR

PART No. H1138

POWFR

LOOM. PART No. AM287-77

CRIMP PIN

PART No. K37

CRIMP

PART

LUG

No.

H1972

In

x

GREY

r

BLACK

CRIMP LUG

No.

H2972

YFLILOW

.r

YELLOW

BK BLACK

AMP PLUG

NO.

K354

-F

CRIMP PIN

4

300"

c

PART No. K37

!

G

ORANGE

K

BLUE

260"

CRIMP LUG

PART

No.

H1972

O

H

GUN CWOL LOOM. PART NO. AM287-24

FIGURE

4.

AM287-0 WIRING LOOM DETAILS

PUSHIPULL

KIT

FOR

W41-SERIES

WIREFEEDERS

Page

9

r-

I

1

I

1

I

""""""_""""""""""

1

ALIGN TOP EDGE OF TEMPLATE

WITH UNDERSIDE

OF

FOLDED FLANGE.

ALIGN RIGHT HAND SIDE EQGE

OF TEMPLATE WITH FOLDED

I

-43-

4mm

DIA.

INSTRUrTlONS FOR USING

THIS

TFMeLALE

REMOVE THIS PAGE FROM YOUR MANUAL.

CUT RECTANGLE

OUT

ALONG DOTTED LINES.

POSITION TEMPLATE AS SHOWN IN DIAGRAM ABOVE.

+

4mm DIA.

+/

I

l

I

1

I

1

CAREFULLY MARK POSITION

OF

FOUR HOLES USING TEMPLATE AS A GUIDE.

,

I

REMOVE TEMPLATE, AND DRILL 4 HOLES, 4mm DIA. IN MARKED POSITIONS.

I

1

I

him DIA.

L"""""""""""""""""~

FIGURE

5.

DRILLING

TEMPLATE

L

WIA Weldmatic 41 Wirefeeder Owner's manual

WIA Weldmatic 41 Wirefeeder Owner's manual

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