WIA Weldmatic 210S Owner's manual

WELDING

INDUSTRIES

OF

AUSTRALIA

A

DIVISION

OF

WELDING

INDUSTRIES

LTD

ACN

004

547

1

l1

Head Office

and

International Sales

5

Allan Street,

Melrose

Park

South Australia,

5039

Telephone

(08)

8276

6494

Facsimile

(08)

8276 6327

OWNERS

MANUAL

WELDMATIC

210s

MODEL

NQ.

CPqO5-0,

REV.

B

MODEL

NO.

CPlO5-11,

REV.

B

Q8196

QUALITY WELDING

PRODUCTS,

SYSTEMS AND S€RV/CE

Page

2

.

WELDMATIC

21

OS

MANUAl

Page

3

SAFETY

Before this equipment is put into operation. the

SAFE

PRACTICES section at the

back of the manual must

be

read completely

.

This

will

help to avoid possible injury

due

to

misuse or improper welding applications

.

CONTENTS

SeC.1

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

IfltrOduCtiQrt

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

P.4

Sec.2

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

Receiving

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

P.4

Sec3

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

Specifications

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

P.5

Sec4

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

Power

Source

Controls

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

P.6

Sec5

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

Installation

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

P.7

Sec.6

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

Normal Welding Sequence

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

P.10

Sec7

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

Basic Welding Information

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

P.10

Sec.8

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

General Maintenance

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

P.13

Sec9

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

Trouble Shooting

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

P.13

Sec.10

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

Service

Information

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

P.74

Sec

.

1

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

Parts Lists

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

P.18

Sec.12

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

Safe Practices

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

R23

FIGURES

Fig.1

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

Power Source Controls

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

P.6

Fig2

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

Remote Wirefeeder Connection

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

P.8

Fig.3

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

Positive Wire Connection

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

P.9

Fig.4

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

Negative Wire Connection

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

P.9

Fig7

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

Gun

Position

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

P

.

12

Fig.8

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

Circuit Diagram

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

P.15

Fig.9

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

Dual

SCR

Control Board

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

P.16

Fig.10

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

Wirefeed Control Board

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

P

.

I?

Fig.?

1

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

Power Source Assembly

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

P.19

Fig.i2

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

Gun Cable

Assembly

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

P.20

Fig.13

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

Wire Drive Assembty

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

P.21

Fig.5

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

‘Good’ Weld

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

P.12

Fig.6

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

‘Bad’

Weld

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

p.12

Fig.14

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

Remote Wirefeeder

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

P.22

Page

4

WELDMATIC

21

OS

MANUAL

The information contained in this manual is set out to enable you

to

properly

maintain your new equipment and ensure that you obtain maximum operating

efficiency.

Please ensure that this information is kept in

a

safe place for ready reference

when required at any future time.

When requesting spare parts, please quote the

model

and serial number

sf

the

machine and part number

of

the

item required. All relevant numbers are shown

in

lists

contained in this manual. Failure to supply this information may result

in

unnecessary

delays in supplying the correct parts.

Gas

Metal Arc Welding (G.M.A.W.) is a basically simple welding process, where

a

consumable wire is fed by motor driven drive rollers

to

a

welding gun, and where

welding current is supplied from the welding power source. The welding arc is struck

between the workpiece

and

the end

~f

the wire, which melts into the weld

pool.

The

arc

and

the weld

pool

are both shielded by gas flow from the gun, or in the case of

"self shielded" wires, by gases generated by the wire core.

The process is very versatile in that by selection of the correct

wire

composition,

diameter and shielding gas, it can be used for applications ranging from sheetmetal

t~

heavy plate, and metals ranging from carbon steel to aluminium alloys.

The WELDMATIC

210%

has been designed

to

be used with consurnable wires in

the range from

0.6mm

to

1.2mm

diameter. The smaller wire

sizes

are used when

welding at lower currents, such

as

sheet-metal applications. Increasing the wire

diameter permits higher welding currents to be selected.

A common application of G.M.A.W. is for welding Mild Steel. In this application, a

Mild Steel

solid

consumable

such

as

WlA

ES6

is used with

a

shielding

gas

of

Carbon

Dioxide, or Argon mixed with Carbon Dioxide. Alternatively, Flux-cored consumables

are available in both

gas

shielded, and 'gasless' self shielding types.

Stainless steel and Aluminium can be welded with G.M.A.W. using the correct

consumable wire and shielding

gas.

2.

RECEtWING

Check

the

equipment received against the shipping invoice

to

make

sure the

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

immediately notify your supplier.

The

GP-105-8

(Internal Wirefeeder) Package contains;

WELDMATIC

210s

Power source.

H

BEXT2-4E218AE

BERNARD

Gun cable,

3

metre, Euro connector.

P

HAlJQIAW Regulator and Ftowgauge. (Argon)

p

(This) Owners Manual,

The

CP185-l

(Remote Wirefeeder) Package contains;

I

WELDMATIC

210s

Power Source.

II

W32-Q

Wirefeeder.

m

AM208-0/10 Inter-connecting lead kit,

10

metre.

W

BEXT2-4E21OAE

BERNARD

Gun cable,

3

metre, Euro connector.

P

HA801AR

Regulator and Flowgauge. (Argon)

I

(This) Owners Manual.

WELDMATIC

21

OS

MANUAL

Page

5

3.

SPECIFICATIONS

Manufactured to Australian standard AS1 966.1-1

985

PRIMARY VOLTAGE

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

240

Volts A.C., Single Phase,

50

Hz.

RATED PRIMARY CURRENT

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

15 Amps

MAX PRIMARY DEMAND

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

30 Amps,

7.2

kVA

(Minimum requirement for supply

from engine driven alternator.

FUSE RATING (Note

l)

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

30 Amps

FITTED

SUPPLY CABLE

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

3010.25

Three Core,

WIRE

SIZE

RANGE

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

0.6mm

-

1.2mm diameter

Heavy Duty PVC

OPEN CIRCUIT VOLTAGE

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

Maximum HIGH Range 35V.

Maximum

LOW

Range

24V.

WIRE FEED RANGE

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

1 to 12 Metres/min

COOLING

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

Fan cooled, air drawn in

through top louwre.

WELDING CURRENT RANGE

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

35

-

205

AMPS

OUTPUT RATING (Note

2)

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

Rated Output: 180 Amps

@

24

Volts,

35%

Duty Cycle.

Note 1. Australian Standards allow the circuit breaker

or

fuse supplying a welder to be

rated at up to twice the rated primary current of the welder.

(AS3000, Clause 2.4.3.4)

Note

2.

Duty cycle is defined in Australian Standard AS1966.1

as

the ratio of arcing

time to

5

minutes

in

any

5

minute period, expressed

as

a

percentage.)

"-@

HIGH-LOW

SWITCH

-@

POWER

ON

INDICATOR

3

INTERVAL CONTROL

SPOT

TIME

CONTROL

WIRE SPEED CONTROL

VOLTAGE

CONTROL

"@

POLARITY

SOCKETS

1.

POWER

ON

INDICATOR

power is connected

lo

the

welder.

'This

is

illuminated

when

the

machine is energised, that

is

when electrical mains

2.

HIGH

-

LOW

SWITCH

This switch provides Coarse adjustment

of

the Output Welding voltage.

This control provides Fine adjustment

of

the

Output Welding voltage. Rotating the

3.

VOLTAGE

CONTROL

control in

a

clockwise direction will increase

the

output voltage.

4.

WIRE

SPEED

CONTROL

clockwise direction increases

the

wirefeed

speed,

increasing the welding current.

5.

SPOT

PIME

CONTROL

When operating

the

machine in Spot Weld mode, this control will

vary

the spot

weld

time. Rotating the dial clockwise will increase

the

spot

weld time, in the range

8.5

-

2.5

seconds.

If

the

Spot

Weld

mode

is not required this feature can

be

turned

off

by

rotating the control anti-clockwise until

it

'clicks' into the minimum

position.

6.

INTERVAL

CQNPROL

When operating

the

machine

in

Cycle

Arc

mode

this

control

sets

the period

between

welds.

The

spot

time controt

sets

the welding period. Rotating the

dial

ctockwise will increase the interval time,

in

the range

0.5

-

2.5

seconds.

If

the

Cycle

Arc

mode

is

not

required this feature can

be

turned

uff

by

rotating both controls fully

anti-clockwise.

7.

POLARITY

SOCKETS

These

sockets

are

provided

to

allow

quick

and

easy

changing

of

the

welding

polarity, simply

by

removing the two

plugs

{flying

lead

and

work

lead)

and

replacing

them

in the opposite sockets.

The

wirefeed

speed

of the machine is varied with this

control;

turning the

dial

in

a

WELDMATIC

21

OS

MANUAL

Paae

7

5.

INSTALLATION

CONNECTION TO ELECTRICAL

MNNS

POWER SUPPLY

The WELDMATIC 210s is supplied with a

3

metre

3

core Heavy Duty

PVC

mains

power supply cable and standard

15

Amp plug.

A

15 Amp plug and socket is recognisable

by

a wide Earth pin. Power Supply authorities require that equipment fitted with a 15 Amp

plug shall

ONLY

be connected to

a 240

Volt, 15 Amp power point.

DO

NOT modify the

The capacity of the main wiring and power outlet supplying

a

welder is selected

according to the

rafed

primary current of the machine. The circuit breaker or fuse,

however must tolerate the periods of maximum demand which occur during arcing. For

this reason, Australian standards allow the circuit breaker or fuse supplying a welder to be

rated at up to twice the

rated

primary current of the welder, (AS3000, clause 2.4.3.4). The

recommended supply fuse is

30

amps. Due to peak current requirements, the electrical

mains supply to welding machines

is

best protected

by

fuses. Circuit breakers may trip

frequently

if

used in this application.

If it becomes necessary to replace the mains power supply cable, use only a cable

with an equivalent or higher current rating. Access to the machine supply terminals is

gained by removing the power-source side panel opposite to the wire-spool enclosure.

FITTING

THE GUN CABLE

The BERNARD BEXT2-4E21QAE gun cable is equipped with a 'Euro' wirefeeder

connector which incorporates all required connection points to the gun cable for welding

current, shielding gas and gun switch control.

To attach the gun cable to the wirefeeding mechanism, engage the mating parts of

the male and female Euro connectors, then rotate the locking ring clockwise to firmly

secure the connection.

FITTING THE

GAS

BOTTLE

Depending on configuration of the cylinder to be used, the gas flowmeter

/

regulator

may be fitted directly

to

the cylinder, or

in

conjunction with an elbow fitting.

BO

NOT

apply

any grease to these joints, and tighten the nuts securely.

Fit the end of the gas inlet hose from the back panel of the machine to the connector

supplied with the flow regulator, and secure with the clamp also supplied.

FITTING THE CONSUMABLE WIRE

The quality of the consumable wire greatly affects how reliably a G.M.A.W. machine

will operate.

For

best results when welding mild steel, we recommend quality WIA

AUSTMIG

ES6.

Dirty, rusty or kinked wire

will

not feed smoothly through the gun cable

and will cause erratic welding. Deposits from the wire will clog the gun cable liner

requiring it to be replaced prematurely.

Place the spool of welding wire onto the spool holder. The location pin should mate

with a hole provided on the wire spool body. Fit the spool retaining 'R' clip supplied.

Check the adjustment

of

the spool brake, which should be set to prevent over-run of

the wire spool at the end of a weld, without unduly loading the wirefeed motor. The

braking can be adjusted by the Nyloc nut using

a

15/16"

AF

or 24mm socket wrench.

Plug.

FsageWWEbDWlATlC

21

OS

MANUAL

FEEDING THE CONSUMABLE WIRE

With reference to Figure

13,

release the pressure screw

(IO),

and rotate the

pressure arm

(8)

to the open position. The end

of

the welding wire can now be passed

through the inlet guide, over the bottom driven roller, and into the output wire guide tube.

Check that the drive roller groove

is

correct for the wire in use. The appropriate size is

stamped on the visible side

of

the installed roller. Check

also

that the correct:

size

contact

tip is fitted at the gun end. Drive roller and tip details are available

in

Section

11

of this

manual.

Return the pressure arm to the closed position and, adjust the compression screw

to

provide sufficient clamping of the drive rolls drive to achieve constant wirefeed.

Do

not

over tighten.

FITTING

REMOTE WIREFEEDER

Where fitted, the

W32-0

remote wirefeeder is connected to the

WELDMATIC

210s

power source using an

AM208

extension

lead

kit. The connection details are shown in the

diagram

below.

GUN CABLE

CONNECTOR

I

CABLE

SEE NOTE

CLAMPS

FIGS1

(b-

W/

CONTROL CABLE

\

W32-0

I

AM208

WIRE FEEDER EXTENSION LEAD

KIT

I

e$&,

RED

-

GREEN

WELDMATIC

210s

POWER SOURCE

DETAIL OF POWER CABLE CONNECTION

FIGURE

2.

REMOTE WIREFEEDER CONNECTIONS

WELDMATIC

21

QS

MANUAL.

Page

9

amur

VOLTAGE

POLARITY.

The

desion

sf

the

WELDMATIC

210s

allows

selection

of

the

Output Voltage

polarity.

POSITIVE

WIRE

Most

G.M.A.W.

is carried out with the workpiece Negative

and

the welding

consumable wire Positive.

To

set

the machine for this condition, insert

the

'WORK'

lead

plug

into the

negative socket

[-),

and the

'GUN

CABLE'

plug into the positive socket

(t),

as

in figure

3.

below.

NEGATIVE

WIRE

Some

"Self-Shielded" flux

cored

consurnables

are

intended

to

be operated with

the workpiece Positive and the consumable wire Negative.

Refer

to

the

manufacturers data for the particular consumable to be used.

To

set the machine for this condition, insert the

'WORK'

lead

plug into the

positive socket

(+),

and

the

'GUN

CABLE'

plug into the negative socket

(-1,

as

in figure

4,

below.

FIGURE

3.

POSITIVE

WIRE

4

l

FIGURE

4.

NEGAliVE

WIRE

Page

10

WELDMATIC

21

OS

MANUAL

6.

NORMAL

WELDING

SEQUENCE

WELD

START

Closing the welding gun switch initiates this sequence of events:

D

The gas valve is energised and gas flow commences;

The Power Source contactor function is initiated. Welding voltage is applied

between the work-piece and the consumable wire.

M

The wire drive motor is energised, wirefeed commences and the arc is

established.

WELD

END

Releasing the gun switch initiates this sequence of events:

The wire drive motor is de-energised, and is dynamically braked

to

a stop;

m

After a short pre-set period, known as the ‘burn-back’ time, the Power-source

contactor function

is

released. This period ensures that the consumable wire

does not ‘freeze’

in

the weld

pool.

To adjust the ‘burn-back’ time, refer

to

Section

10.

D

The gas valve is de-energised and the flow

of

shielding gas ceases.

7.

BASIC WELDING

INFORMATION

CHOICE

OF

SHIELDING

GAS

The choice of shielding gas is largely determined by the consumable wire to be

The recommended shielding gases for use with the WELDMATIC

210s

are:

Mild

Steel

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

Argon

f

5

to

25%

Carbon Dioxide;

m

Aluminium

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

Argon;

used. Many proprietary shielding gas mixtures are available.

M

Stainless Steel

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

Argon

t

1

to

2%

Oxygen.

Consult your gas supplier

if

more

specific information is required.

WELDMATIC

21

OS

MANUAL

Page

1

SHIELDING

GAS

FLOW

RATE

In

G.M.A.W,,

one

of

the functions of the shielding gas

is

to protect the molten

weld pool from the effects of oxygen

in

the

atmosphere. Without this protection the

weld deposit becomes 'honeycombed' in appearance, an effect which

is

described as

weld porosity.

In draft-free conditions the gas flow rate required to give adequate protection is

typically

10

litres/min. In situations where drafts cannot be avoided,

it

may

be

necessary to increase this rate and/or to provide screening

of

the work area.

Weld

porosity can also be caused by air entering the

gas

stream through a

damaged hose, loose gas connection,

or

from restriction in the nozzle, such as from

excess build-up

of

spatter.

ESTA5LlSHlNG

A

WELD

SEITlNG

the two variables that are adjusted in order to obtain a stable arc are;

Once the consumable wire type, wire size and shielding gas have been chosen,

H

Wirefeed speed,

m

Welding arc voltage.

The wirefeed rate determines the welding current; increasing the feed rate

increases the current, and decreasing

it

decreases current. The selected wirefeed

rate must be matched with sufficient arc voltage;

an

increase of wirefeed rate requires

an increase

of

arc voltage.

If

the voltage

is

too

low

the wire will stub

and

stutter, and there will not be a

steady arc.

If

the voltage

is

too high the arc will be long with the metal transfer within

the arc occurring as a series

of

large droplets.

The welding current should be chosen to suit the thickness of the metal to be

welded.

it

is

important to check that the deposited weld provides sufficient strength

to suit the apptication.

Page

l2

WELDMATIC

21

OS

MANUAL

A

"good" weld will have the characteristics illustrated in figure

5.

The weld has

penetrated into the parent metal, fusing the root

of

the joint where the two plates

meet, and the weld blends smoothly into the side walls.

A

"bad" weld

is

shown

in

figure

6.

The weld has not penetrated the joint root,

and

there is poor side wall fusion. This

lack

of

fusion would normally be corrected by

increasing the arc voltage, or by increasing both wirefeed rate and arc voltage to

achieve

a

higher current weld setting.

FIGURE

5.

"GOOD"

WELD

FIGURE

6.

"BAD"

WELD

GUN

POStTION

below with the nozzle end pointing

in

the

direction of travel.

For

"down

hand" fillet welding,

the

gun is normally positioned as in the figures

FIGURE

7.

GUN

POSITION

l

~

DUST

Care should be taken to prevent excessive build-up

of

dust

and dirt within the

welding power source.

It

is recommended that at regular intervals, according to

the

prevailing conditions, the machine covers

be

removed and any accumulated dust

be

removed by the use

sf

dry, low pressure cornpressed air, or

a

vacuum cleaner.

WIREFEED

In

order to obtain the most satisfactory welding results from the

G.M.A.W.

process, the wirefeed must he smooth and constant.

It

is therefore important

to

observe the

following

points;

8

Keep the gun cable iiner clear

of

dust and swarf

build-up.

When replacement

becomes necessary,

fit

only the correct liner

to

suit the gun cable model.

See

Section

1

I.

The

build-up

of

dust

in

a

cable liner

can

be minimized

by

regular

purging

of

the liner with dry compressed air. This may

be

conveniently done

each

time

the wire

spool

is

replaced.

S

Replace the welding tip

as

it becomes worn.

~9

Keep the wire drive mechanism

clean,

Periodically check the drive rollers for

wear and for free rotation.

Check that the consumable wire

spool

holder rotates smoothly and that the

braking action is not excessive. This aiso

may

be conveniently done each

time the wire is replenished.

9.

TROUBLE

SHOOTING

WIREFEED

R

Erratic wirefeed is the

MOST

LIKELY

cause

of

failure

in

all Gas Metal Arc

Welding.

It

should therefore

be

the

first point cheeked when problems occur.

Refer to the section above.

N

Check for correct

gas

flow rate at

the

welding torch n~szle

and

ensure there

are

no

gas

leaks.

The

gun

nozzle

must

be

free

from

spatter

and firmly

attached

to

the welding gun to ensure that air

is

not

drawn into the

shielded

area.

M

Check that the shielding gas selected is correct for the consumable wire in

use.

WELDING

CIRCUIT

m

Ensure

that

the

work clamp is securely tightened onto the work-piece

so

that

good

electrical contact

is

achieved. Check

also

that the output polarity

selected

is

appropriate for the consurnable

in

use.

H

Surface contamination

sf

the work-piece by

water,

oil,

grease, galvanizing,

paint, or oxide

tayers

can severely disturb the welding arc resulting

in

a

poor

weld.

Should

this condition occur, surface cleaning

of

the work piece will

be

beneficial,

Page

14

WELDMATIC

21

OS

MANUAL

WIREFEED

/

ARC

VOLTAGE RELATIONSHIP

tf

the consumable wire is stubbing into

the

workpiece, and

a

steady arc cannot be

obtained,

it

is likely that the arc voltage

is

set too low to suit the wire speed.

To

correct this situation either increase arc voltage, or decrease the wire speed.

If

the arc length is

too

long,

the

arc voltage

is

too high

ks

suit the wire speed.

To

correct this, increase wire

speed

or decrease arc voltage.

p18

WELDING

CURRENT

Check that Mains Supply is available at the WELDMATIC

210s

Power

Source, i.e.

that the fan is running

and

the indicator light is illuminated.

Check continuity of

the

welding current circuit,

i.e.,

work lead, work clamp and

gun cable connections.

The WELDMATIC

2105

welding ower source incorporates

an

inbuilt over

temperature thermostat which wili trip

i

P

the welding load exceeds the operating duty

cycle.

In

this event the machine will not deliver welding current until the machine has

cooled sufficiently. The thermostat will reset automatically

-

do

not switch the

machine off

as

the cooling fan will assist tke resetting

of

the thermostat.

If

the forgoing checks have been made and have not revealed

the

fault condition,

a QUALIFIED SERVtCE person should

be

consulted.

The main electrical components of the WELDMATIC

210s

are listed below, with

reference to the following circuit diagram.

Welding Rectifier Assembly.

This comprises twelve high-current rectifier diodes mounted on aluminium

heatsinks, electrolytic filter capacitors, transient protection network and

discharge resistors.

Wetding Transformer.

The Primary winding is tapped to provide High

/

Low range adjustment,

and the secondary is centre tapped. Maximum open circuit

secondary wottage

=

24

-

0

-

24

Votts

AC

with

HIGH

range and the maximum

voltage selected.

Wirsfeed control Board

See following description.

Duat

SCR

Control

Board (including

Dual

SCR)

See

following description.

Control Transformer

The secondary winding is centre-tapped, providing

an

output

voltage

=

30

-

0

-

30

Volts

BC.

Welding Inductance.

HIGH

-

LOW

Range

Switch.

Limiting Inductance.

Gas

varve.

WELDMATfC

21

OS

MANUAL

Page

15

""""_

~

I

l

COARSE

'

VOLTAGE

I

RED

I

26

,

SELECTOR

I

WH

I

Lo

If

l

24BU

15A

5Ehz

Er---"--l

n

-1

F'

I

=CTRLl

T/F

I

-

_I

l

'=l

==

SCR NODULE

ELK YEL GRY BLU

I I

FAN1

7

CPIBZ-51

FAN2

DUAL SCR

ASSEMBLY

(

i

nc

lud

i

ng

SCR.

1

THERNISTAT

RECTIFIER

GAS

VALVE

cd

P

I

-1

L

-

P1

"""

l

I

L-

l

CPlE5-lE

WIREFEED BRD

PWR.ON

DCEP

with

Gas

Solid

lines

/

G/SW

YEL

v

SPOT

RED CCWl

BLU CCWl

FIGURE

8.

WELDMATIC

210s

CIRCUIT

DIAGRAM

Page

16

WELDMATIC

21

OS

MANUAL

DUAL SCR

CONTROL

BOARD

CP102-51

The Dual SCR Control board

and

associated Dual

SCR

together provide two

circuit functions;

m

Welding transformer

ON

/

OFF

control in response to an output

of

the

wirefeed control board, (the contactor function).

E

Output voltage control by means

of

phase-shifting

of

the Welding transformer

primary voitage, as adjusted by the front panel

‘VOLTAGE

CONTROL’

potentiometer.

With

HIGH

range selected, the

‘VOLTAGE

CONTROL’ provides adjustment of

the

welding transformer secondary voltage over the range

11

-

24

Volts

A.C.,

measured

from the centre tap

to

one end

of

the

winding.

Connections to the board are detailed in the diagram below.

FIGURE

9.

DUAL

SCR

CONTROt

BOARD

WELDMATIC

21

OS

MANUAL

Page

17

The

Wirefeed control board provides

the

following circuit functions:

B

Wirefeed motor

ON

/

OFF

control

in

response to

the

gun-switch.

IE~

Speed

controt

of

the

wirefeed motor.

’Burn-back’ control.

m

Braking

of

the

wirefeed

motor

at

end

of

weld.

Spot-weld timer.

n

Interval

timer.

Control

of

the

gas

solenoid valve.

Connections

to

the

board,

and Service points

are

detailed

in

the

drawing below.

The

circuit

is

factory

adjusted

to

provide

a

maximum

drive roller

speed

of

126

rpm.

DUAL

SCR ASS’Y

--

TO

CONTROL

T/Ffoo:

30.

DUAL

SCR

ASS’Y-(,

GAS

VALVE

<

L

P2

0

:)WIREFEED

MOTOR

:)WIRE

SPEED POT.

:>POWER

‘ON’

LED

--DUAL

SCR

ASS’Y

1).

GUN

SWITCH

:).SPOT TIME POT.

1).

INTERVAL

POT.

BURNBACK ADJUSTMENT

-/

L

MOTOR

RUN/BRAKE RELAY

FIGURE

10.

WIREFEED

CONTROL

BOARD

Page

18

WELDMATIC

21

OS

MANUAL

1

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

CP

185-1

8

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

Wirefeecl Control PCB

2

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

CP102-51

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

Dual SCR Control

PCB

(inc.Dual

SCR)

3

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

CP105-Q/1

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

Rectifier Assembly inc.Thermostat)

4

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

CP10

5-1

3

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

Transformer Assem

b

ly

5

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

§A140-0/2

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

25 Dia Panel Socket

6

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

CP102-I4

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

Inductance

7

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

CP105-20

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

Limiting Inductance

8

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

CPlO5-31

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

Capacitor Bank Assembly

Includes

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

CP102-12/8

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

Capacitor

lO,OOOpF,

63V.(4)

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

sP.101-12/9

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

Discharge resistor

(2)

9

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

CP42-24

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

Base

Assembly

10

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

CP105-39

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

Centre Panel Assembly

1

l

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

CP42-25

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

Baffle Panel

12

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

cp105-33Y

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

Front Panel

13

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

CP42-22Y

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

3ack Panel

I4

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

CP42-29Y

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

To

Cover

15

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

CP42-26Y

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

Si

CP

e

Cover Fixed (not shown)

16

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

CP42-27Y

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

Side Cover

~

Fixed Lower

l7

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

CP42-28Y

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

Side Cover

-

Opening (not shown)

18

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

W29-1/20

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

Slam Action Latch not shown)

19

........................ CP105-30

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

Rectifier Mounting

b

racket

20

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

CF42-30

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

PCB

Cover Panel

21

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

cP42-0/3

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

Wheel Rubber 160 Dia

22

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

MC1

1

-53/6

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

Ratchet Cap

23

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

MK6/2

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

Terminal Block

24

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

CP27-0/

15

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

Coolin Fan

25

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

CPI 02-0/16

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

Contro

Y

Transformer

26

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

CPlOt-0 18

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

Gas Valve

27

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

W1 1-1

1

/

1

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

Hose Tail

30

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

W1C66-0/ 8

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

Primary

Flex

&

Plug

31

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

W27-2

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

Wirefeed Motor

&.

2

Roll

Drive

33

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

CP105-21

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

boom for Wirefeed

PCB

Includes

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

CB27-1 1/26

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

Potentiometer,50K, Switched

(2)

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

CP10’1-11/8

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

Potentiometer,lOK,AT’ype(l)

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

W17-0/1

l

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

Indicator Light

34

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

W5-10/19

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

Small

Knob

2

35

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

W1

1-0/16

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

Large Knob 2

36

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

62513

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

Gas

Hose,

B

ii

ack Rubber

41

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

SCG830

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

Bottle Chain

44

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

CP3-0/23

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

Rubber Grommet

45

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

MC14-0/10

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

Conduit Bush,

Male

46

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

MC‘I

4-0/1

1

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

Conduit Bush, Female

47

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

CP105-23

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

Work Lead Assembly

Includes

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

CLG300

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

Work Clamp 3OOAmp

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

SA32-5/1

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

25 Dia Lead

Plug

48

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

AMI

77

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

S

ool

Holder Assembly

65

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

MC1 1-32/2

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

Nylon Bush

(2)

66

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

W1

1-13

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

Motor Insulator

(2)

68

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

TC396-1

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

Euro Adaptor

2.4

Stem

69

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

CPl02-28

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

Diode Protection Assembly

73

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

CPlQ5-37

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

Busbar Link

74

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

CP42-39

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

Handle Assembly

58

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

CP102-0/17

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

tp

1GH-LOW

Switch

NOTE

Far

the

Remote

Wirefeeder

ackage,

Items

31

E;

48

are

deleted,

and

item

6%

becomes

Rubber

Grommet,

Part

No,

c!

P102-27.

WELDMATIC

21

OS

MANUAL

Page

19

T

L

FIGURE

11.

WELDMATIC

210s

POWER

SOURCE

ASSEMBLY

Page

28

WELDMATIC

21

OS

MANUAL

BEXT2-4E21OAE GUM ASSEMBLY

1

......

BE4392

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

Nozzle

15.

...

BE4E213B

.......

End Fitting

2

......

BE7497

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

Contact tip Q.6mm 16

....

BE4305

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

Cone Nut

........

BE7488

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

Contact tip 0.8mm 17’....BE2660001

......

Terminal

........

BE7489

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

Contact tip 0.9mm 18

....

BE1520008

......

Clamp

........

BE7490

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

Contact tip 1.2mm 19.

...

BE252801

7...

...

Strain Relief

3

......

BE4335

...........

Head 20

....

BE1470007

......

Bushing

4

......

BE4323R

.........

Cap 21

....

BE1 8801 35..

....

Strain Relief, rigid

5

......

BE4780

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

Nut Insulator 22

....

B€2280002

......

Screw

6

......

BE1 3701 17

......

Insulator

23

....

H2072

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

Insulated Link

9

......

BE1370116

......

Body Tube 24

....

BE4816

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

Nut

8

......

BE1780006

......

Handle Kit

25

....

BE5060

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

Euro Block

9..

....

BE5662..

..........

Trigger

26

....

BE4421

............l

Q‘

Ring

IO..

..

BE1 880004..

....

Screw Kit 2’7

....

BE431

10

..........

Liner

0.9

-

1.2mm

14

....

BE8681TE

.......

Cable 3m.

To replace liner: Disconnect gun cable assembly from the

euro

adaptor on the

machine case, remove nozzle (1) and head (3). Withdraw

old

liner from the wire feeder

end. insert new liner and refit gun cable assembly to Euro adaptor

on

the machine case.

At the gun end, compress the liner within the gun cable, then cut

it

one contact tip length

past the end of the body tube

(9).

Refit head,

tip

and nozzle.

FIGURE 12. BEXT2-4E240AE GUN

&

CABLE ASSEMBLY

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WIA Weldmatic 210S Owner's manual

WIA Weldmatic 210S Owner's manual

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