WIA Weldmatic 200 Owner's manual

WELDMATIC

200

MODEL NO.

CP15

CAT.

7522

8/81

FROM SERIAL NO.

1527-1

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 SPARE PARTS, QUOTE THE MODEL

NO.

AND

SERIAL NO. OF THE MACHINE AND THE PART NO. OF THE ITEM

IN UNNECESSARY DELAYS IN SUPPLYING THE CORRECT PARTS.

REQUIRED. FAILURE TO SUPPLY THIS INFORMATION WILL

RESULT

WELDING INDUSTRIES OF AUSTRALIA PTY. LTD.

SALES AND SERVICE DIVISIONS

Melbourne

429 4766

Sydney

534

2144

Newcastle

61

1668

Adelaide

352

3022

Perth

361 7088

Brisbane

44

1391

STATE AGENTS

Launceston

31

7004

Darwin

81 6427

&

84 3076

OPERATING AND MAINTENANCE INSTRUCTIONS

WELDMATIC

200

(CP15)

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

inform-

ation presented herein

should

be

given careful consideration

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 losses 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 Model 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&6

Welding Data Table

6

Parts List

CP15-Q1

7

Assembly Drawing CPP5-01

8

Circuit Diagram CP15-C2

,

9

Accessory Leads

AM118

Mobile Kit Assembly

Safety .Practices

Guarantee Card

10

11

-1-

STANDARD

UNIT

The

construction of the standard package plant

has

been

des-

igned 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 Asse.mbly.

Separate operating and maintenance instructions

are

provided

for the

wire

feeder

and gun cables.

1.

POWER

SOURCE

-

FEATUIiES

-

The standard

C.P.

rectifier power source

is

housed in

a

drip-

proof enclosure. Lifting lugs

are

provided for crane trans-

portation. Wheel mounting with four solid. rubber tyred wheels

is

provided,

the

two front wheels

are

steerable permitting

easy movement

in

restricted

floor space.

A

push bar

is

pro-

vided on the front of

the

machine and

a

gas cylinder

carrier

with

a

support

bracket

and chain at

the

rear.

A

swivel mount-

ing for

the

wire

feeder

is

fitted

to

the top of

the

power source.

A

l10

volt plug socket

is

located on

the

rear

panel

for

connec-

tion

of

gas

preheater when welding with

C02

gas shield.

Located on

the

front panel

are

a

coarse voltage selection

switch (incorporating power

ON/OFF),

fine voltage selection

switch, control

fuses,

wire

feeder

plug socket and

rectifier

power output 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

W17.

b)

W17

Semi-automatic

wire

feeder with spot

timer

AM128.

c)

"Hobart"

spool

gun welding unit model SP9 with

CV2

controller.-

d)

"Mini-mig" push and

pull

gun and control.

4.

WELDING

CAPACITY

~I._"

Power Source Capacity

is

as

follows:-

200

Amps,

25

volts,

100%

duty cycle.

-2-

5.

"

SUPPLY AND WEEDING CABLES.

",".-

-.

Power Sources are suitable for connection

to

a

415

volt

50

Hertz

3

phase supply.

The reconmended fuse

size,

primary cable size and welding

cable size are as follows:-

a) Fuse

-

15

amp

b)

Primary Cable

-

4

core

32/0.20

T.R.S.

c) Welding Cable

-

792/0.20

T.R.S.

6.

SHIELDING GASES.

a)

Welding Grade C02 for

all

mild and alloy steel weldiny in

thicknesses ranging from

1

nun

upwards.

b)

Argon/C02 or Argon/Oxygen mixtures for

all

applications

on

low currents requiring minimum of spatter on sheet steel

and for stainless steel welding,

c) Argon/Oxygen and Argon/C02 mixtures for prime welding of

stainless

steel.

cl)

Argon (pure) for

all

aluminium welding.

"

7.

SETTING

UP

TJNIT

FOR

OPERATION.

a) General

Assembly

"

of Packaged Plant

The power source is shipped on

its

skid

base. Wheels, handle,

bottle carrier and bottle cradle should be assembled as shown

on drawing

AM118.

W17

Wire Feeder

is

fitted

to

the top.of

power source in the special swivel mount on the machine. Fit

the W14-16 pivot pin assembly to the wire feeder and ensure

fibre thrust washer is on the pin before locating in the swivel

mounting. Check that wire feeder

is

free to swivel in all

directions,

if

necessary apply a small amount of graphite

"___.I

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 ascer-

tained before connecting the machine. Access to supply csnnec-

tion

terminals in machine may be gained by removing left hand

side panel.

Use

a flexible

4

core primary cable for portable

machines and cla.mp 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.

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 inser.t

-3-

gun cable into

socket of

wire

feeder

output guide. Connect

"Gas

Hose" and

"Gun Switch" leads to

respective sockets.

d)

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 jumper lead

from

'l+''

socket ommachine to terminal lug on gun

cable.

The work

lead ("negative") should be plugged into the

''-'l

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

comprising power cable, gas

hose

and control cable (four core)

are

required in accordance with

the

desired length,standard

length

available

from

stock

is

9

metres.

e)

Wire

Feeder

and Gun

Cable

Fit

a

spool

of

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 accordance

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.

0.8

mm

=

0.030"

0.9

mm

=

0.035"

1.2

mm

=

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

corxect

size

for

wire

being used.

-4-

WELDING

OPERATION

INSTRUCTIONS

I

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

a11

welding connections and

plugs for tightness particularly "worlc" 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

full-y 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 throuyh

the

gun cable to

the

arc

at a constant speed,

unchanged except

when

reset

by the

'wire

speed' control. The

hiyher

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

is

a

combined high/low range

ON/OFF

switch

working in conjunction

with

a

"fine" selector

switch

giving

20

voltage steps.

The

following sequence of weld.setting

is

recommended:-

a) Consult typical

weld

setting

chart.

b)

Select

welding current most sui-ted to

the

application by

following the settings

of

wire

speed and voltage shown on

the

set-ting

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

wi.11

be very convex.

If

the

voltage

is

too high,

met.al

trans-

fer

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

an.d

with

the cooling fan operating this

will

take

approximately

10

minutes.

A

check should be made

to

ascertain

the

reason for

the overheating such

as

fan not operating or

air

flow

restric-

ted. 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

(

11.

MAINTENANCE

a)

Power Source

Apart from

the

fan the rectifer 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 sh-ould

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

II

'I

ll

I'

)

14,900

service

hours..

(see

Wire-Feeder Instructions Manual)

The drive rollers and

the

inner

wire

guides should be kept clean.

If

necessary, blow

off

the

inside

of the

wire

feeder

with

com-

pressed

air.

c)

Gun and Cable

Remove any spatter which

mic&

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

importance

that the welder

wear

protective clothing providing sufficient

safety.

-6-

13.

STOPPAGES

AND

THEIR

ELIMINATION

The machine should be checked only by

a

fully skilled

electric-

ian.

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

Ill,

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 loc-

ation of the de.fect.

018mm

COARSE

V0

LT

S

:*O30”)

WIRE

SPEED

DIAL SETTING

-

WIRE SPEED

DIAL

SETTING

-

1.2mrn

COARSE

FINE

(1

0

4

5”)

VOLTS

SETTINGS GIVEN

FOR

C02

SHIELDIWG

GAS.-

FLOW

RATE

8-

lOLlTRES/MIHU1IE.

USE

THIS

CHART

AS

A

PRELlWlladARY

SETTING

GUIDE. TO ‘TUNE’ EACH

WELD

SEPTIHG, ADJUST

WIRE

SPEED

ONLY.

FOR

FURTHER

DETAILS,

lHCLUDlNG

USE

OF

ARGON

MIXED

GAS

REFER

MANIHA1.

If mixed gases

are

to be used, the above chart

will

still

pro-

vide

a

useful setting guide, however for optimum results,

voltage adjustment may be necessary

-

in general the voltage

setting

will

need to be reduced. Recommended gas flow

rate

for mixed

gas,es

is

10

-

15

litres/minute.

ITEI

NO.

1

2

3

4

5

G

7

8.

9

10

11

12

13

P4

15

16

17

18

L9

20

21

22

23

24

l1

25

?G

!7

PART

NO.

CP15-34

CP15-12

CP15-14

CP15-01/4

CP24-0/5

CP15-35

CP15-0/7

CP15-0/9

w1-22

W1-23

CP25-0/18

CP25-0/3.9

CP15-0/14

2P15-32

ZP15-33

.

c1P15-27

2P15-28

W3

5

JP15-0/20

K14-1/14

VIN4

4

UN81

:P-l5-0/2 8

:P15-01/26

:P15-30

DESCRIPTION

BASE ASSEMBLY

TRANSFORIWR

ASSEMBLY

INDUCTANCE ASSEMBLY

FAN BLADE

FAN MOTOR

WCTIFIER ASSEMBLY

3EATER PLUG SOCKET

mLDING CONTACTOR

INDICATOR LIGHT

?USE HOLDER

?INE VOLTAGE SELECTOR SWITCH

30ARSE VOLTAGE SELECTOR SWITCH

:ONTROL PLUG

?RONT PANEL

3ACK

PANEL

cop

COVER

jIDE PANELS

IUTPUT TERMINAL ASSEMBLY

:ONTROL TERMINALS

IUPPLY TERMINALS

'YPE NO./SERIAL

NO.

PLATE

:YE NUTS

'ERMINAL CONNECTION NAMEPLATE

:ABLE ENTRY BUSH

!ABLE ENTRY BUSH

'RIMARY CABLE

IOOM

ASSEMBLY

*

IVOT MOUNTING FOR WIRE FEEDER

L

8

9

c-

'

-T

"

I

1

n

j

p

L.

MIG

ACCESSORY

KIT

LEADS

FOR

CP15

POWER

SQURCE'Wl4P(17.

WIRE

FEEDER.

i,

NUT1

TAIL.

F

Ln

II

0

1

0

c

.G

0

.os

,.

"

0

r

,*-.

4.

Fire and ExplosTon Prevention

Causes of €$re and explosTon

aye:-

Combustibles reached by the arc, flame,

fly-

ing sparks, hot slag, or heated material; misuse

of

compressed gases and cylin-

ders; and short circuits.

Be aware .that flying sparks

or

falling slag can pass through cracks, along pipes,

through windows or doors

,

and through wall or floor openings, out. of sight of

the goggled operator. Sparks and slag can

fly

LO

metres.

To

prevent fires and explosions:- Keep equipment clean and operable, Eree of

oil, grease, and

(in

electrical parts) of metallic particles that can cause short

circuits.

If combustibles are

in

area, do

NOT

weld or cut. Move the work

if

practicable,

to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage

areas, ventilators. If the work can not be moved, move combustibles at least

10

metres away out of reach of sparks and heat; or protect against ignition with

suitable and snug-fitting fire-resistant covers or shields.

Walls touching combustibles on opposite sides should not

be.

welded

on (or

cut).

Walls,ceilings, and floor near work should be protected by heat-resistant covers

or shields.

Fire watcher

must

be standing by with suitable fire extinguishing equi.pment

during and for some time after welding

OK

cutting

if:

(1)

combustibles (including building construction) are within

LO

metres.

(11)

combus.tibles are further than

10

metres but can be ignited by sparks.

(11.1)

openings (concealed

or

visible) in

floors

or

walls

within

10

metres

(1V)

combustibles adjacent to walls, ceilings, roofs, or metal partitions

"""-_ll-

may

expose

combustibles to sparks.

can be ignited by radiant ox conducted heat.

After

work

is

done, check that are'a

is

free of sparks, glowing embers, and flames.

An

empty container that held combustibles, or can produce flamable vapors when

heated,

must

never be welded on or cut, unless container has first been cleaned

as

described

in

AS.1674-1.974,

the

S.A.A.

Cutting and Welding Safety Code. This

includes

:

a thoxough steam or causkic

..

cleaning...-(or

a

solvent or water washing,

depending on the combustible's solubility) followed by purging and inerting

with

nitrogen or carbon dioxide, and using protective equipment as recommended

in

AS.1674-1974.

Water-filling

just

below working level may substitute €or inerting.

Ilollow castings

or

containers

must

be vented before welding or cutting. They

can

explode. Never weld or cut where the air

may

contain flammable dust, gas, or

liquid vapors such as petrol).

5.

Shock Prevention

Exposed conductors

or

other bare metal in the welding circuit, or ungrounded

electrically alive equipment can fatally shock a person whose body becomes

a

con-

ductor. Ensure that the machine

is

correctly connected and earthed. If unsure

have machine installed by a qualified electrician. On mobile or portable equipment,

regularly inspect-condition of trailing power.leads

...

and..connectincj plugs. Repair

or replace damaged leads.

6.

Electrode Holders and Connectors

Fully insulated electrode holders should,bc -used...:.

Do

,not

use

holders with protruding

screws. Fully insulated lock-type connectors should be.used to join welding cable

lengths.

7.

Terminals

Terminals and other exposed parts of electrical units should.have insulated knobs

or

covers secured before operation.

SAFE

PRACTICES

IN

USING

WELDING

EQUIPMENT

Produced by Welding Industries of Australia Pty. Ltd.

i.n

the interests of

improving operator safety. These notes should be considered only as a basic

guide to Safe Working Habits.

A

full

list

of

Standards pertaining to industry

is

available from the Standards Association of Australia, also various State

Electricity Authorities, Departments

of

Labour and Industry or Mines Depart-

ment and other Local Health or Safety Inspection Authorities may have

additional requirements.

1.

A

neat uncluttered work area makes for safe working habits.

2.

Burn

Prevention

The welding arc

is

intense and visibly bright.

Its

radiation can damage eyes,

penetrate lightweight clothing, reflect from light-coloured surfaces, and burn

the skin and eyes. Skin burns resemble acute sunburn, those from gas-shielded

arcs are more severe and painful.

Wear protective clothing

-

Leather (or asbestos) gauntlet gloves, hat, and

safety-toe boots. Button shirt collar and pocket flaps, and wear cuffless

trousers to avoid entry of sparks and slag.

NEVER

LOOK

AT

AN

ARC

WITHOUT

PROTECTION.

Wear helmet with safety goggles or glasses with side shields underneath,

appropriate filter lenses or plates (protected by clear cover glass). This

is

a

MUST

for welding or cutting, (and chipping) to protect the eyes from

radiant energy and flying metal. Replace cover glass when broken, pitted,or

spattered.

Avoid

oily

or

greasy clothing.

A

spark

may

ignite them. Hot metal such as

electrode

stubs

and workpieces should never he handled without gloves.

Ear plugs should be worn when welding in overhead positions

or

in a confined

space.

A

hard hat should be worn when others

work

overhead.

Flammable hair preparations should not be used by persons intending to weld

or cut.

3.

Toxic Fume Prevention

Adequate ventilation

is

essential. Severe discomfort, illness

or

death can

result from fumes, vapors, heat, or oxygen enrichment

or

depletion that welding

(or cutting) may produce. Prevent them with adequate ventilation.

NEVER

ventilate with oxygen.

Lead, cadium, zinc, mercury, and beryllium bearing and similar materials when

welded (or cut) may produce harmful concentrations

of

toxic fumes. Adequate

local exhaust ventilation

must

be used, or each person in the area as

well

as

the operator

must

wear an air-supplied respirator. For beryllium, both

must

be used. Metals coated with

or

containing materials that emit fumes should

not be heated unless coating

is

removed from the work surface, the area

is

well

ventilated, or the operator wears an air-supplied respirator.

Work

in a confined space only while

it

is

being ventilated and, if necessary,

while wearing air-supplied respirator.

Vapors from ckdorinated solvents can be decomposed by the heat

of

the arc (or

flame)

to

form

PHOSGENE,

a

highly

toxic

gas, and lung

and

eye

irritating

products. The ultra-violet (radiant) energy

of

the arc can also decompose

trichlorethylene and perchlorethylene vapors to form phosgene.

Do

not

WELD

or cut where solvent vapors can be drawn into the welding

or

cutting atmosphere

or where the

radiant

energy can penetrate to atmospheres containing even minute

amounts of trichlorethylene

or

percholorethylene.

WIA Weldmatic 200 Owner's manual

WIA Weldmatic 200 Owner's manual

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