WIA Weldarc Combi Owner's manual

WELDING

INDUSTRIES

OF

AUSTRALIA

A

BtVISIBN

OF

WELDtNG

INDUSTRIES

LTD

ACN

004

547

1

Head

Office

and

International

Sales

5

Atfan

Street, Mekose Park

South

Australia,

5039

Telephone

(08)

276

6494

Facsimile

(Q8)

276

6327

OWNERS

MANUAL

WELDARG

COMB1

HB

WlQDEb

NO.

MC83-0,

REV.B

03/93

QUALITY

WELDING

PRODUCTS,

SYSTEMS

AND

SERVlCE

Page

2

WELDARC COMB1 HD MANUAL

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.

1

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 part

no. of the item required. Failure to supply this information may result in unnecessary delays

in

supplying the correct parts.

SAFETY

Before this equipment is put into operation, the safety 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.

GENERAL

The WELDARC COMB1 HD

is

a versatile DC only constant current type welding power

supply intended for MMA (Manual Metal Arc), TIG (Tungsten Inert Gas) and Arc Gouging

processes. The design

of

the unit allows it to be

used

with minimum ancillary equipment,

ie. basic electrode holder or TIG torch, while also supporting full remote control features

where required.

A feature of the WELDARC COMB1 HD when in the TIG mode is ELECTRONIC TOUCH

starting of the arc which makes the

use

of high frequency arc starting attachments un-

necessary.

The WELDARC COMB1 HD has two welding output characteristics. The first is for general

purpose MMA and TIG welding, while the second has specially tailored characteristics to

suit Cellulose and Low Hydrogen type MMA electrodes in positional welding.

i

CONTENTS

SECTION

PAGE CONTENTS

1.

.....

3

......

SPECIFICATIONS

2.

.....

3

......

RECEIVING

3.

,

.

,

4

.

,

.

,

.

INSTALLATION

4.

.....

6

......

CONTROLS

5.

.....

8

......

WELDINGSET-UP

6.

.....

9

.......

GENERAL MAINTENANCE

7.

.....

9

......

TROUBLE SHOOTING

8.

.....

10

......

CONTROL PRINTED CIRCUIT BOARD

9.

.....

12

......

SPARE PARTS LISTS

FIGURE PAGE DESCRIPTION

1.

.....

5

......

CQNNECTION SUPPLY FLEXIBLE CABLE

2.

, ,

.

,

.

5

.

,

.

,

TRANSFORMER VOLTAGE SELECTION TAPS

3.

.....

6

......

FRONT PANEL CONTROLS

4.

.....

7

......

REMOTE CONTROL SOCKET CONNECTIONS

5.

.....

11

......

MAIN CONTROL PCB OVERLAY

6.

.....

13

......

POWER-SOURCE ASSEMBLY

7.

.....

14

......

RECTIFIER ASSEMBLY

8.

.....

15

......

WELDARC COMB1 HD CIRCUIT DIAGRAM

WELBARC COMB1

HD

MANUAL Page

3

1

l

SPECIFICATIONS

MACHINE TYPE

..........

MC83

EQUIPMENT CLASS

........

Heavy Duty.

POWER SOURCE TYPE

.....

Constant Current.

PRIMARY SUPPLY

........

415

/

440

Volts

:

3

phase

:

50

Hz.

RATED INPUT CURRENT

.....

30 Amps.

MAXIMUM DEMAND CURRENT

.

40

Amps.

OPEN CIRCUIT VOLTAGE

....

70

Volts.

WELDING OUTPUT

........

400

Amps

@

32 Volts,

60%

Duty Cycle.

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

300

Amps

@

32 Volts,

100%

Duty Cycle.

2.

RECEIVING

In

general it is a good practice to move the equipment to the site of installation before un-

packing. Use care in order to avoid damage

to

the items enclosed.

Check the equipment received against the shipping invoice to make sure the shipment is

complete and undamaged.

If

any damage has occurred

in

transit immediately notify Welding Industries of Australia or

their authorized agent.

For

all

requested information related to this equipment give the correct Model Identifica-

tion and Serial Number. This is located on a name plate attached to the right-hand lower

front of the machine.

Page

4

WELDARC COMBt HD MANUAL

3.

INSTALLATION

3.1

Machine Location

Where possible, in choosing a site for any welding power-source, consideration should be

given to the following points;

Availability of electrical and shielding gas supplies where required.

Accessibility

for

the replacement of consumables, i.e. gas bottles, and for any future main-

tenance requirements.

The power-source must be positioned

so

that the free flow

of

cooling air through the

machine is not impeded, such as by placing the rear of the machine too close to

a

wall.

Protection from wind and driven rain; Breezes blowing through an open doorway can result

in degradation

of

the weld shielding gas coverage, which can cause weld porosity.

If

such

a

site is unavoidable, consideration should be given to the use of portable welding screens

of a suitable material. The outflow of cooling air from the welding Power-source can also

cause similar problems, and the machine should be positioned with this in mind.

Airborne dust particles will always accumulate in vented equipment, particularly that with

forced air cooling. Excessive internal buildup of dust can often be the cause

of

premature

machine faiture. At all times endeavour

to

position the machine to minimize the intake of

contaminated air, particularly that containing metallic particles such

as

from grinding

operations.

3.2

Suitable Mains Voltages

The WELDARC

COMB1

HD

IS

designed for connection to a

3

phase,

50

hertz electrical

mains power supply.

A

'Neutral' conductor is not required. The Maximum Demand of the

equipment is 40 Amps per phase, with

a

Rated Input current

of

30

Amps per phase.

3.3

Connection

To

Electrical Mains

Power

Supply

All electrical work shall only be undertaken by a qualified electrician.

The WELDARC COMB1 HD is supplied with

a

5

metre

4

core

56/0.30

(4mm2) Heavy Duty

PVC mains power supply cable. This cable should be correctly connected to

a

suitable

3

phase plug top or fixed connection.

When making connection

to

the machine supply terminals, ensure that local codes are

adhered to, and that the EARTH connection is securely made.

The mains supply cable should only be replaced with cable of equivalent or greater cur-

rent rating.

Access to the machine supply terminals, the welding transformer and the control trans-

former voltage selectors is gained by removing the Power-source side panel adjacent to

Amp and Volt meters.

WELDARC

COMB1

HD

MANUAL Page

5

Pass

the supply flexible cable through the bushed cable entry in the machine back panel.

Fit the supplied cable clamp ensuring that there

is

sufficient free cable to prevent strain on

the electrical connections. The three phases are terminated at the terminal strip and the

EARTH cable

Is

terminated at the adjacent EARTH terminal as indicated in

FIG

'l.

EARTH

FIGURE

1.

CONNECTION

SUPPLY

FLEXIBLE CABLE

3.4

Transformer

Voltage Selection

Taps

The Welding and Control Transformer voltage selection

taps

are

as

illustrated

below:

NOTE: It

is

mandatory that the correct electrical mainsvoltage taps

be

selected before this

equipment is operated. Failure to do

so

may void warranty.

'

MAIN

TRANSFORMER

VOLTAGE

SELECTION

TAPS

MAIN

TRANSFORMER

CONTROL

TRANSFORMER

FIGURE

2.

TRANSFORMER VOLTAGE SELECTION TAPS

Page

6

WELDARC

COMB1

HQ

MANUAL

4.

FRONT

PANEL

CONTROLS

SWllCH

TORCH

I

HOAYAL

8

LATCHING

VOLTS

AMPS

FIGURE

3.

FRONT PANEL CONTROLS

Power

Off/On

Use

to energise or de:energise the Power-source.

Power On Indlcator

This is illuminated when the Power-source is energised, indicating that the control circuits

are activated.

Fuse

A

Three amp slow-blow

type

3AG which protects the contactor circuit.

Ammeter

The Ammeter indicates the welding current (amps average).

Voltmeter

The Voltmeter indicates the welding voltage (volts average).

Maln Current Control

This provides stepless control of the Welding Current

up

to

a

maximum of

400

Amps.

If

a

Remote Current Control potentiometer

is

also connected, the main

current

control sets

the

maximum

'welding current, while the Remote Control sets the anal welding current

as

a

percentage

of

the main setting.

In

this

way,

an operator

can

be

prevented

from

inadver-

tently exceeding

a

desired maximum welding current limit.

Post Gas Control

This provides stepless adjustment of the period of Post-gas

flow

following

reiease

of

the

Torch switch in T.I.G. mode. There

is

no

gas

flow

if

the

MMA

mode

is

selected.

TIG

I

MMA Switch

Set this switch to correspond to the type of welding to be undertaken. In the

"A

mode,

the welding output characteristics are tallored for

MMA

welding, and the

gas

valve

is

prevented from operating.

WELDARC COMB1

HD

MANUAL Page

7

Contactor

This switch

is

used in the absence

of

a Torch-switch to set the Welding output ON.

If

a

Torch switch is in use, place the Contactor switch in the

OFF

position.

Gouging

This switch

is

set to the

ON

position when the machine is to be used for Arc Gouging. Note

that the Contactor switch must

also

be in ON position.

Hot Start

This function can be selected

to

assist arc initiation, especially for

TIG

welding at

low

weld

currents. The facility provides

a

short period of increased weld current immediately follow-

ing weld initiation which assists in stabilizing the arc.

Latching

This switch selects the mode

of

operation

of

the Torch switch. With Latching

OFF,

the

welding output is ON only white the Torch switch is held closed.

With Latching

ON,

the welding output is toggled ON

by

a

momentary operation

of

the torch

switch, and

OFF

by a second momentary operation of the torch switch. The Latching ON

mode can be used to reduce operator fatigue during long weld periods.

1

2

3

4

5

6

7

8

Torch switch

(No

connection)

Remote

Current Control

Remote

Current

Control

Remote Gas Valve

Remote

Gas

Valve

(No

connectlon)

FIGURE

4.

REMOTE CONTROL

SOCKET

CONNECTIONS

Page

8

WELDARC

COMB1 HB MANUAL

5.

WELDING

SET-UP

M.M.A.

*

Connect the Electrode and Work leads to the COMB1

HB

in the Polarity to suit the

electrode type in use. The output "tow Hydrogen and Cellulose" provides enhanced

welding characteristics for those electrode types. The maximum output of this ter-

minal is limited

to

200

Amps.

*

Adjust the Welding current to the desired setting.

*

Turn the Contactor switch ON to energise the welding output.

T.I.G.

Welding

Connect the shielding gas supply to the COMB1 HD. An internal gas valve controls

gas flow as required.

Connect the torch and work leads to the COMB1 HD welding output terminals. For

TIG welding, use electrode negative polarity. Select the upper "General Purpose"

+v8 output terminal.

Set the gas flow rate to suit the welding procedure.

Select the approximate welding current.

To set the welding output

ON,

use either the front panel Contactor switch or the Torch

switch where fitted.

If

the Latching function is selected, only a momentary closing of

the torch switch is required.

To initiate the arc, touch the tungsten electrode onto the workpiece, and then retract

the torch in

a

StTIooth movement.

Extinguish the arc by releasing the torch switch, or where the Latching mode is

selected, by a momentary closing

of

the torch switch. Hold the torch steady for the

period of post gas flow.

Gouging

*

Connect an appropriate Gouging torch

to

the COMB1

HD,

and to the compressed air

supply. For Arc gouging, use electrode positive polarity.

*

Set the output current in accordance with the size of carbon electrode to be used.

*

Set the Gouging and Contactor switches

ON.

WELDARC COMB1

HD

MANUAL Page

9

6.

GENERAL MAINTENANCE

Care must 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 dust accumulation be removed by the use of dry,

low pressure compressed air, or a vacuum cleaner.

Ensure that the WELDARC COMBt

HD

power source is disconnected from the Mains volt-

age power supply before any covers are removed.

7.

TROUBLE

SHOOTING

Listed below are some common faults which should be checked before a Service Tech-

nician

is

called.

Check that mains supply is available at the WELDARC COMB1

HD

power source,

i.e., that the fan is running and the indicator light is on.

Check continuity of the welding current circuit, i.e., work lead, work clamp and

electrode holder or Torch connections.

Inspect, and replace

if

necessary the fuse on the WELDARC COMB1

HD

power

source front panel. Replace

fuses

only with the correct type (3AG) and correct cur-

rent rating (3 Amp).

If

TIG welding, check for correct type and flow of shielding gas, and for any leaks.

Establish that the welding leads are fitted for the correct polarity.

TIG

is

conducted

with electrode negative, while Gouging has the electrode positive. Stick electrodes

are generally operated electrode negative, but check the electrode manufacturer's

data.

Check that the WELDARC COMB1

HD

front panel switches are set correctly for the

process in use.

If

a

faulty Remote Current Control or Gun-switch

is

suspected, this connection can

be unplugged and the front-panel controls tried.

Page

10

WELOARC

COMB1

HD MANUAL

8.

CONTROL

PRINTED

CIRCUIT

BOARD

Main

Control

PCB

MC8340

This

PCB contains the circuit elements which control the

6

thyristors

(SCR's)

which form

the main welding rectifier.

It incorporates

a

closed

loop

control system which

acts

to maintain the DC output current

of

the welding rectifier at the desired

level

as set

by

the operator 'CURRENT control.

'

Figure

5

shows the external connections

to

the MC824

0,

and

also

the location

of

the diag-

nostic LED's and test points. The function

of

each of these is described in the lists

below.

LED

#

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

TEST POINT

A

B

C

D

E

F

G

FUNCTION

-1

5

VDC REGULATED

-

CURRENT AMPLIFIER

+l5

VDC REGULATED

-

CURRENT AMPLIFIER

-1

5

VBC

REGULATED

-

MAIN POWER SUPPLY

-1-15 VDC REGULATED

-

MAIN POWER SUPPLY

REMOTE POT. CIRCUIT CONTINUITY

MASTER POT.-CIRCUIT CONTINUITY

PHASE SENSING VOLTAGE P3 PINS 6,8

PHASE SENSING VOLTAGE P3 PINS 7,8

PHASE SENSING VOLTAGE P3 PINS

6,7

TRIGGER POWER SUPPLY

SCR

1

TRIGGER POWER SUPPLY

SCR

2

TRIGGER POWER SUPPLY SCR

3

TRIGGER

POWER

SUPPLY

SCR

4

TRIGGER POWER SUPPLY

SCR

5

TRIGGER

POWER

SUPPLY

SCR

6

VOLTAGE

LEVEL

OR

SIGNAL

CIRCUIT COMMON

RAMP

1

RAMP

2

RAMP 3

CONDUCTION WAVEFORM

START MODE ON- SCRS DISABLED /OFF- DURING WELDING

TYPICAL RAMP

WAVEFORM

(RAMPS

l

,2

&

3)

WELDARC

COMB1

HD

MANUAL

Page

11

L€D

7Q

1

eJ

/C/2

QLED6

/C/B

QL€d//

c

ON

PROL

..~.

.

'L

SCR

f

SCRP

SCR3

SCR4

.$

SCA5

K

SCR6

FIGURE

5.

MAIN

CONTROL

PCB

OVERLAY

MC82-10

Page 12 WELDARC COMB1 HD MANUAL

9.

SPARE PARTS

LISTS

9.1

Power

Source

Assembly

ITEM

#

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

19

20

22

24

25

33

34

37

37.1

37.2

37.3

37.4

37.5

37.7

48

49

50

51

52

53

57

PART #

MC83-l1

MC83-12

MC83-26

MC83-14

MC82-10

MC82-0/5

MC83-20

MC83-21

CP34-18

CP34-19

MC83-22

MC82-0/8

CP33-0/10

MC82-0/11

CP29-0/20

CP34-OI14

W1 -33/1

W5-10/19

AM1 6

08029F

W 1

1

-0/16

W1 -23

ClP281/25

CLP281 F25

W1 7-W11

CP34-36/2

CP29-0/39

W 1-20

W5- 1

0/9

CP34-44/01

MC83-25

MC82-23/1

CP22-3/13

CP3-0/4

MC35-0/6

CP62-l8

MC83-16

DESCRIPTION

BASE ASSEMBLY

TRANSFORMER ASSEMBLY

INDUCTANCE ASSEMBLY

RECTIFIER ASSEMBLY

SCR CONTROL BOARD

CONTROL TRANSFORMER

FRONT PANEL

BACK PANEL

TOP COVER

SIDE COVER

SIDE COMPONENT' TRAY

CONTACTOR

AMMETER

VOLTMETER

ON/OFF SWITCH

PLUG SOCKET

GAS VALVE

KNOB

OUTPUT TERMINAL

EYE NUT

KNOB

FUSE HOLDER

MALE BUSH

FEMALE BUSH

MAIN LOOM ASSEMBLY

INDICATOR LIGHT

POTENTIOMETER

SWITCH

H.F. FILTER BOARD

PRINTED CIRCUIT BOARD ASS'Y

RESISTANCE STRIP

MOUNTING INSULATOR

FAN BLADE

FAN MOTOR

FAN MOUNTING BRACKET

SUPPORT BRACKET

WELDARC COMB1 HD MANUAL

Page

l4

9.2

Rectifler

Assembly

ITEM

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

P

PART#

MC83-1411

MC83-1412

MC83-1413

CP62-21

I1

CP62-2 1

12

CP15-l313

CP3-9/8

CP3-0/30

MC83-1414

MC83-1415

MC83-1416

W1 1-13

MC1

1

-3U2

MC83-14/7

MC82-15110

DESCRIPTION

HEATSINK

DIODE HEATSINK

MOUNTING RAIL

SCR (THYRISTOR)

BOX

CLAMP

DIQDE

THERMOSTAT

AMMETER SHUNT

CONNECTION LINK

RESISTOR MOUNTING BOARD

MOUNTING

INSULATORS

NYLON INSULATING BUSH

RESISTOR 10 OHM 40 WATT

CONNECTION RAIL

-

SHORT

CONNECTION RAIL

-

LONG

FIGURE

7.

RECTIFIER ASSEMBLY

SAFE

PRACTICES

IN

USING

WELDING

EQUIPMENT

These notes are provided in the interests

of

improving operator safety. They should be considered

only as a basic guide to Safe Working Habits.

A

full list

of

Standards pertaining

to

industry is avail-

able from the Standards Association of Australia, also various State Electricity Authorities, Depart-

ments

of

Labour and Industry

or

Mines Department and other Local Health or Safety Inspection

Authorities may have additional requirements.

EYE

PROTECTION

NEVER

LOOK

AT AN ARC WITHOUT PROTECTION. Wear a helmet with safety goggles or glas-

ses

with side shields underneath, appropriate filter lenses protected by clear cover glass. This is

a MUST

for

welding, cutting, and chipping

to

protect the eyes from radiant energy and flying metal.

Replace the cover glass when broken, pitted,

or

spattered.

BURN PROTECTION.

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. Burns resulting from gas-

shielded arcs resemble acute sunburn, but can be more severe and painful.

Wear protective clothing

..

leather

or

heat resistant gloves, hat, and safety- toe boots. Button

shirt

collar and pocket flaps, and wear cuffless trousers to avoid entry

of

sparks and slag.

Avoid oily or greasy clothing. A spark may ignite them. Hot metal such as electrode stubs and

.

workpieces should never

be

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 are working overhead.

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

TOXIC FUME

PREVENTION.

Adequate ventilation with air

Is

essential. Severe discomfort, Illness or death can result from fumes,

vapors, heat, or oxygen depletion that welding or cutting may produce.

NEVER

ventllate wlth

oxygen.

Lead, cadmlum, 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 beryl-

lium,

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 &ir-sup-

plied respirator,

Vapours from chlorinated solvents

can be

decomposed by the heat

of

the

arc (or flame) to form

PHOSGENE,

a highly toxic gas, and lung and

eye

irritatlng products. The ultra-violet (radiant) ener-

gy

of

the arc can

also

decompose trichlorethyfene 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 mlnute amounts of

trichlorethylene or perchoiorethylene.

FIRE

AND EXPLOSION PREVENTION.

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 operator. Sparks and slag can travel

up to

10

metres from the arc.

Keep equipment clean and operable, free of oil, grease, and (in electrical parts) of metallic particles

that can cause short circuits.

If combustibles are present in the work 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

IQ

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.

A

person acting as Fire Watcher must be standing by with suitable fife extinguishing equipment

during and for some time after welding or cutting

if;

*

Combustibles (including building construction) are within

10

metres.

*

Combustibles are further than

10

metres but can be ignited by sparks.

*

Openings (concealed

or

visible) in floors or walls within

10

metres may expose combustibles

*

Combustibles adjacent

to

walls, ceilings, roofs,

or

metal partitions can be ignited by radiant

or

to sparks.

conducted heat.

After work is done, check that area is free of sparks, glowing embers, and flames.

Any tank

or

drum which has contained combustibles can produce flammable vapors when heated.

Such

a

container must never be welded on

or

cut, unless it has first been cleaned as described in

AS.1674-1974, the S.A.A. Cutting and Welding Safety Code. This includes

a

thorough steam

or

caustic cleaning (or asolvent or waterwashing, depending on the combustible’s solubility) followed

by purging and inerting with nitrogen

or

carbon dioxide, and using protective equipment as recom-

mended in

AS1

674-1

974. Water-filling just below working level may substitute for inerting.

Hollow 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 vapours.

SHOCK

PREVENTION.

Exposed conductors

or

other bare metal in the welding circuit, or ungrounded electrically alive equip-

ment can fatally shock a person whose body becomes a conductor. 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 connecting

plugs. Repair

or

replace damaged leads.

Fully insulated electrode holders should be used.

Bo

not use holders with protruding screws. Fully

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

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

or

covers secured

before operation.

WELDARC

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MANUAL

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WIA Weldarc Combi Owner's manual

WIA Weldarc Combi Owner's manual

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