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
REQUIRFD. FAILURE TO SUPPLY THIS
INFORMATION
WILL
RESULT IN UNNECESSARY DELAYS IN SUPPLYING THE CORRECT
PARTS.
WELDING INDUSTRIES
OF
AUSTRALIA PTY. LTD.
WELDMATIC
180s
SINGLE PHASE
MODEL NO. CP19
WITH
W20
WIREFEEDER
2/83
FROM SERIAL NO.
1901-1
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.
Melbourne
429 4766
Sydney
534 2144
Newcastle
61 1668
Adelaide
352
3022
Perth
361 7088
Brisbane
44 1391
Launceston
31 7004
Darwin
81 6427
&
84 3076
OPERATING
AND
MAINTENANCE
INSTRUCTIONS
""-
VELDMATIC
180s
(CP19) SINGLE
PHASE
WITH
W20
WIRE
FEEDERS
INTRODUCTION
GENERAL
This
manual
has been prepared especially for use
in
familiarizing personnel
with the design, installation, operation, maintenance, and troubleshooting
of this equipment.
All
information presented herein should be given
careful consideration
to
assure
optimum performance of this equipment.
RECEIVING/HANBLING
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 Lriiury due
to
misuse
or
improper welding applications.
CONTENTS
GENERAL
DESCRIPTION
SETTING
UP
FOR
OPERATION
WELDING
OPERATION INSTRUCTIONS
MAINTENANCE
INSTRUCTIONS
WELDING
DATA
TABLE
PARTS LIST CP19-0
ASSEMBLY DRAWING CP19-0
CIRCUIT
DIAGRAM
CP19-Cl
DRAWING
W2O-0
WIRE
FEEDER
PARTS LIST W2O-0
DRAWING
w2-44/
50
TWO
ROLL
DRIVE
PARTS LIST W2-44/50
TABLE
W2
DRIVE
ROLL
&
GUIDE
COMBINATIONS
SAFETY PRACTICES
GUARANTEE
CARD
PAGE
NO,
1
2
3
5
6
7
8
9
10
11
12
13
14
1
STANDARD
UNIT
The construction of the standard package plant has been designed for installation
and operating in
a
wide variety
of
applications, such
as
high production
factories and general fabrication shops.
"WELDMATIC"
CP19 Plant consist
of
three
basic
units:-
1j
Constant Potential Rectifier Power Source with controls
for W20
Wire
feeder.
2)
Semi-Automatic
Wire
feeder.
3)
Welding Gun and Cable Assembly,
Separate operating and maintenance instructions are provided for the gun cables.
1.
POWER SOURCE
-
FEATURES
The standard
C.P,
rectifier power source
is
housed in
a
drip proof
enclosure. Wheel mounting with four solid tyred wheels
is
provided,
the two front wheels
are
steerable permitting easy movement in restricted
floor space. Provision
is
made for mounting the gas bottle on the back
of
the machine with tray, cradle and chain. Located on the front panel
are
a
voltage selection switch, gas to gun connection, gun cable plug
socket,
wire
speed controls, spot and stitch welding controls. Work
lead and positive
cable
lead to gun are permanent connects to power source.
2.
CONSTRUCTION
The power source
is
a
Constant Potential Silicon Diode Rectifier
D.C.
Welder, with
a
single phase transformer and
a
rectifier
bridge, Connected
in the output circuit
is
an inductance unit providing the "inductance" or
degree of slope necessary 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.
It
also includes the controls
for
the operation of the
W20
Wire feeder,
such
as
the
wire
speed control, gas purge and
wire
inch switch, spot and
cycle
arc
timer
controls.
3.
WELDING
PROCESS
Gas
metal
arc welding within the capacity of the power source can be
carried out with W20 Wire feeder.
4.
WELDING
CAPACITY
Power Source capacity
is
as
follows:-
180
Amps, 25
Volts,
35%
Duty Cycle.
2
5,
SUPPLY
AND
WELDING
CABLES
power Sources are suitable for connection to
a
240 Volt,50 Hertz,
1
Phase
supply
The recommended fuse size, primary cable size and welding cable size are
as
follows:-
a)
Fuse
-
20 Amp
b) Primary Cable
-
3
Core 50/0,25 T.R.S.
c)
Welding Cable
-
792/0,20 T.R.S.
6.
SHIELDING
GASES
a)
Welding Grade
CO2
for
all
mild and alloy
steel
welding in thicknesses
ranging from
lm
upwards,
b)
Axgon/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.
a).
Argon (pure) for
all
aluminium welding,
7.
SETTING
UP
UNIT
FOR
OPERATION
a)
Connection to Mains Supply
Note: This work should only be done by
a
qualified electrician. The power
source
is
designed for connection to 240 Volt,
50
Hertz,
1
Phase supply
and the supply voltage should be ascertained before connecting the machine.
Access
to
supply connection terminals in machine may be gained
by
removing
the top cover.
Use
a
flexible
3
core primary
cable
for portable machines
and clamp 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.
b) Connection of Cables/Hoses
,
etc.
Connect the gas hose from the
rear
of power source to the regulator/
flowmeter on the gas bottle ensuring
all
connections are tightened firmly.
c)
Wire
Feeder
and
Gun
Cable
Fit
a
spool wire to the
wire
feeder. 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
DRIVE
ROLL
COMBINATION
TABLE
for correct selection of
wire
feed rolls and input guides.
The
gun
cable and gun
are
normally delivered with the contact tip and liner
spring
for
wire size nominated, but check that both
are
correct size for
wire being used,
8.
9.
3
WELDING
OPERATION
INSTRUCTIONS
Single Function check and Operation
Unit
is
now ready for operation, but prior to commencing welding, the
following "functions check"
is
recommended. Switch on power source
and check
air
flow. Check
all
welding connections for tightness,
particularly "work" clamp. Next ensure that all control cables and gas
hoses
are
securely connected. Open gas cylinder and check contents
gauge for adequate gas supply.
Set gas flow in accordance with welding requirements,
at
the same
time,
check
that
gas
flow
is
adequate from gun nozzle. To feed
wire
through
the gun cable conduit, first carefully straighten the free end of the
electrode
wire,
then cut
it
in the centcre
of
the straightened section.
With the top feed roll gate assembly open, pass the electrode
wire
end
through the input
wire
guide, over the bottom drive roller and into the
gun cable liner end. Ensure that the wire fits into the drive roller
groove. The top feed roll gate assembly can now be lowered into position
and the compression screw engaged.
NOTE:
Compress the spring with sufficient force only to provide positive
wire
feed.
Excessive
pressure between the drive rollers
will
result in
deformation of the electrode
wire
and
will
act
against smooth
wire
feeding.
Using the gun switch, advance the
wire
down the gun
cable
and out of the
welding tip, Cut wire approximately
lOmm
from the welding tip,
NOTE:
When the Welding Power Source contactor
is
energised, the two roll
drive and
wire
spool etc.
is
live
(at
the welding potential) with
respect to
the
work
lead.
Set the voltage selector switches in accordance with required voltage
(.see
Welding Table) and
set
the "Spot Time"
-
"Cycle
Arc"
switch to
the
mid
position for continuous welding, Unit
is
now ready for welding.
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 through
the gun cable to the arc
at
a
constant speed, unchanged except when
reset
by the
"wire
speed" control. The higher
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
nuniber of steps
by
a
"voltage selector" switch, giving
LO
voltage settings.
The following sequence
of
weld
setting
is
recommended:-
a)
Consult the "Typical Weld Setting" chart.
b) Select welding current most suited to the application by following
the settings
of
wire
speed and voltage shown on the setting chart.
To "tune" each weld setting adjust wire speed only.
-
L
4
9.
SETTING
OF
WELDING
CURRENT
AND
VOLTAGE
(cont Id)
c)
If voltage
is
too low for the application,
wire
"stubbing"
will
occur, particularly
at
start of weld and weld contour
will
be
very convex. If the voltage
is
too high, metal transfer
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.
10.
SPOT
TIME/CYCLE
ARC
TIMER
CONTROLS
The
CPlO
Power Source
is
fitted with the additional feature
of
being
able
to
provide accurate, timed,
"arc
spot welds" and "stitch welding".
The time
is
controlled by potentiometers on the front panel and
a
switch selects the three welding modes described below.
a)
The selector switch in the
OFF
position. The operator
will
detect
no change in
wire
feeder operation.
b) The selector switch
in
the SPOT position. The operator
will
note
the operation of the wire feeder
is
modified
as
follows. On closing
the gun switch, welding
will
commence
as
usual. Later, at some
time
interval, welding
will
cease. The actual length of this
"time
interval"
is
set
by the spot
time
control. Fully anticlockwise
is
minimum, approx.
9
seconds, and fully clockwise
is
maximum, approx.
2.5 seconds.
NOTE:
Gas
flow continues until gun switch
is
released. The gun
switch has overall control and
will
stop the operation
at
any
time
if released.
c)
The selector switch in the
CYCLE
ARC
position. The operation of
the
wire
feeder
is
modified such that
a
series
of Itspot"
is
produced
whilst the gun switch
is
held on, These "spots''
are
similar
to that
described
in
2
and
are
controlled in the
same
way. The
time
interval
between spots
is
set
by the interval control. Fully anticlockwise
minimum approx.
0
seconds. Fully clockwise,
maximum
approx. 2.5
seconds.
Gas
flow
is
initiated on depression of gun switch and
is
uninterrupted until gun switch
is
released. Again, gun switch has
overall control and process stops immediately on
release
of gun switch.
11.
SAFETY DEVICES
In the event of the power source becoming overheated, the thermostats
on the diode heat sinks
will
operate preventing further welding. The
thermostats
will
automatically
reset
and 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 restricted,
Fuse
provided for control circuit and
wire
feeder
protection
is
mounted on the printed circuit panel inside power source,
Access to fuse and panel may
be
gained by removing left hand side cover
or top cover. Fuse size
is
5 A.S.B.
5
12.
MAINTENANCE
a)
Power Source
Apart from the fan, the rectifier 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 should 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)
Wire
Feeder
The
wire
feed motor/gearbox
is
pre-packed with grease and needs no other
lubrication. Change the grease after approximately 14,000 service hours.
The drive rollers and the inner
wire
guides should be kept clean. If
necessary, blow off the inside
of
the wire feeder with compressed
air.
c)
Gun and Cable
Remove any spatter which might adhere to the nozzle bore
so
that the
shielding gas outflow
is
not impeded. The condition of the contact tubes
should be regularly checked. Damage 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 Instructions on
Gun
Cables).
13.
WELDING
OPERATION
Never observe the arc with unprotected eyes.
It
is
of importance that
the welder
wear
protective clothing providing sufficient safety.
14.
STOPPAGES
AND
THEIR
ELIMINATION
a)
Power Source
The machine should be checked only by
a
fully skilled electrician.
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 two terminals
L1
and L2 on the primary terminal block
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 location
of
the defect,
b)
Wire
Feeder
DRIYE
MOTOR
WILL
NOT
TURN
WHEN
GUN
SWITCH IS
OPERATED
AND
SPEED
CONTROL
IS SET
TO
THE
DESIRED SPEED.
1.
Check that
30
volts
A.C.
Power
is
turned on and
a11
fuses
are
intact.
2.
Press Gun Switch if motor does not turn, visually check printed
circuit board and make sure that
all
componentry, wiring, and
electrical connections
are
secure. Check motor relay on printed
circuit board and ensure
it
is
operating correctly, also check
Gun Switch and switch wires.
6
14,
'
STOPPAGES-
AND
THEIR
ELIMINATION
(cont 'd)
3.
FUSES
BLOW
F33PEATEDLY
WHILST
WELDING.
Check
to
see that a
slow-blow
type fuse
is
being used. Standard fuses may heat
and
blow even at
low
motor loads.
-_
4.
Motor may be overloaded
-
check:-
(a)
Wire
Reel Brake
-
Reel shou1.d
only
have enough brake pressure
applied
to
prevent
it
from over-running after the drive
motor
stops.
(b)
Feed
Roll
Pressure should only be sufficient to push the wire
evenly. Excessive pressure can deform both flux cored
and
solid
wires.
(c)
Dirt
in
the
wire
feed tube
-
Blow out.
(dl Obstruction in tip-ream out. Replace tip when worn oversize.
(e)
Buckles
in
weld
wire
-
Cut
out.
(
fj
.Rusty
Wire
-
Replace.
(g)
Check Feed
Roll
gear teeth
for
interfering material, dirt
or
wire "bits".
6mm
VOLTS
1.
1
35558
I2rnm-
..
I
.
..
.VOLTS
I
56
789
If mixed
gases
are to be used, the Bbove chart
will
still
provide
a
useful
setting
guide,
however for optimum results, voltage adjustment may
he
necessary
-
in general the voltage setting
will
need
to
be reduced,
Recommended
gas
flow
rate for mixed
gases is
10
-
15
litres/minut.e.
:TEM
NI
_._
1
2
3
4
4.1
4.2
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
27.1
28
29
30
31
32
33
34
P
PART
NO
CP19-12
CP17-25
CP17-26
CP17-18
CP15-13/2
CP15-13/3
CP19-11
Wll-28
CP17-0/9
CP17-0/10
CP17-0/11
CP15-01/4
CP17-0/14
WIN44
Wll-0/16
W5-10/19
CP28-14/10
W1-
33/1
w11-11
W17-14
CP19-14
CP17-30
CP17-14
CP19-13
CP17-17
CP19- 0/24
CP19-0/25
MC14-0/10
)
MC14-0/11
)
CP19-0/28
AM119-3
W1-35/1
\~711-6/13
AM14
3
AA2
7
DRAWING
NO.
CP19-0 PARTS LIST
Issue
No.
1
DESCRIPTION
BASE ASSEMBLY
TRANSFORMER ASSEMBLY
LIMITING INDUCTANCE
&
WELDING INDUCTANCE ASSEMBLY
RECTIFIER ASSEMBLY
SEMIKRON DIODE SKR 240/04
SEMIKRON DIODE SKN 240/04
WIRE:
FEEDER CONTROL P
.C.
PANEL ASSEMBLY
CURRENT RELAY COIL
CONTROL TRANSFORMER 240V-31V, 220
VA
CONTACTOR
VOLTAGE CONTROL SWITCH
FAN BLADE
FAN
MOTOR
-240V,
50Hz
TYPE
NO.
/SERIAL
NO
.'
NAMEPLATE
POTENTIOMETER
KNOB
-
WIRE
SPEED
POTENTIOMETER
KNOB
.-
SPOT
6r
CYCLE
ARC
TIME
P.C. BOARD MOUNTINGS
GAS
VALUE
HOSE
BARB
GAS VALVE CONNECTION
FRONT PANEL
BACK PANEL
BAFFLE
&
COMPONENT MTG, TRAY
TOP COVER
SIDE PANELS
LOOM ASSEMBLY
-
POWER SOURCE
LOOM ASSEMBLY
-
WIRE FEEDER
GAS HOSE
CABLE ENTRY BUSH
CASTOR WHEELS
REAR
WHEELS
PLUG SOCKET
S
UPPLY FLEX
CAPACITOR
-
GREEN CAP
0.lmfd
LOOV
BOTTLE CRADLE ASSEMBLY
'G'
TYPE
WORK
CLAMP
r
T
t
I
t
9
/-
IO
I
I
I'
l
[TEM
1
1
2
3
4
5
6
7
8
9
10
11
w20-11
W20-13
W20-14
W17-01/6
W2-44/50
AM1
3
8
MCl1-32/2
Wll-13
AM133
WIN44
CP3-0/23
DRAWING NO.
W2O-0
PARTS LIST
Issue
No.
1
v.
"
DESCRIPTION
WIRE
FEEDER
BASE
ASSEMBLY
WIRE:
FEEDER FRONT PLATE
SPOOL MOUNTING BRACKET
WIRE
FEED MOTOR
2
ROLL DRIVE ASSEMBLY
CLEAR DUST COVER FLAP ASSEMBLY
NYLON INSULATING B.USHES
MOUNTING INSULATORS
SPOOL HOLDER ASSEMBLY
TYPE NO ,/SERIAL
NO.
NAMEPLATE
RUBBER GROMMET
12
:TEM NI
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
PART NO
W2-44/1
W2-44/2
W2-44/18
W2-44/19
4920
W2-44/20
W2-44/6
W2-44/7
W2-44/8
W2-44/14
W2-44/15
W2-44/16
W2-44/032
W2-16/1
W2
a..
.
.
. . . .
.
W2-44/10
03061111
W2-17
W2-44/12
08040
0305029
05104
050512
061214
0612 3
06038F
W2-44/13
08074H
W2-44/5
d2-44/21
W2-44/22
3516103
13
DRAWING
W2-4/1/50
PARTS
LIST
Issue
No.
1
DESCRIPTION
2
ROLL DRIVE BODY
2
ROLL DRIVE TOP ROLLER HOUSING
ENTRY BUSH
BERNARD CABLE ADAPTOR
BERNARD QUICK DISCONNECT
GUIDE TUBE
TENSION
ARM
ADJUSTING NUT
TOP
ROLLER
SHAFT
TOP
ROLLER BUSHING
BUSHING RING
FLANGED BUSHING RING
BALL BEARING
6203
ZZ
DRIVING ROLLER
BOSS
BOTTOM DRIVE ROLL
-
SEE TABLE
PIVOT
SHAFT
SLOTTED PAN HEAD SCFEW
M3
X
6
aASHER
WIRE
INPUT GUIDE
BRASS
WASHER
8mm
I
.D.
,
3cREw
?OCmT
SET
SCREW
M5
X
10
3EX. SHOULDER SCREW
5/16"
X
1/2"
20UNTERSUNK SOCKET
SCREW M6
X
12
ZAP
HEAD SOCKET
SET
SCREW
M6
X
12
3EX. NYLOC NUT
3/8"
B.S
.W.
SPRING
4EX.
LOCKBUT
M8
INSULATION BUSHES
FLAT WASHER
24mm
I.C.
X
34
O.D.
IEX. BRASS NUT
M24
X
1
SOCKET CAP HEAD
SCREW M5
X
16
,
I.
14
W2-44/50
TWO
ROLL
DRIVE-ROLLER
8
WIRE
GUIDE
ACCESSORY
TABLE
__I___
~.
-__~
I____""
~
"
-
A
I
STEEL
I
BEARING
ROLLER
PLAIN
VEE
ROLLER
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
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