WIA Weldmatic 320 Owner's manual

WELDMATIC

3

2

0

MODEL NO. CP26

CAT.

7523/26

1/8

0

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

NUP4BER

OF

THE MACHINE AND THE PART

NO.

OF THE ITEM REQUIRED.

DELAYS IN SUPPLYING THE CORRECT PARTS.

FAILURE TO SUPPLY THIS INFORMATION WILL RESULT IN UNNECESSARY

WELDING INDUSTRIES

OF

AUSTRALIA PTY. LTD.

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

WELDMATIC 320 (,CP26)

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/HANDLING

Prior to installing this equipment, clean a11 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

applications.

CONTENTS

General Description

Setting up for Operation

Welding Operation Instructions

Maintenance Instructions

Welding Data

-

Table "C"

-

Parts List CP 25-03 Issue

4

-

Assembly Drawing CP 25-03 Issue

4

Circuit Diagrams

-

CP25-C4

Mobile Kit Assembly

-

AM51

Safety Practices

Guarantee Card

improper welding

PAGE

NO.

1

2-3

4

5

6

3

8

9

-1-

STANDARD

UN

I

T

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" Plants consist of three basic units

:-

l.

Constant Potential Rectifier Power Source

2.

Semi-Automatic Wire Feeder

3.

Welding Gun and Cable Assembly.

Separate operating and maintenance instructions are provided for

the wire feeder and gun cables.

1.

POWER SOURCE

-

FEATURES

The standard C.P. rectifier power source is housed in a drip proof

enclosure. Lifting lugs are provided for crane transportation.

For units with wheel mounting, four solid rubber tyred wheels are

provided; the two front wheels are steerable permitting easy move-

ment in restricted floor space. A push bar is provided on the

front of the machine and a gas cylinder carrier with a support

bracket and chain at the rear. A

110

volt plug socket is located

on the rear panel for connection 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 volt-

age selection switch, control fuses, wire feeder plug socket and

rectifier power outlet 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 induct-

ance 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.

3.

WELDING PROCESS

Gas

metal arc welding within the capacity Of the Power Source can

be carried out with the following equipment:-

a) Sem.i-automatic wire feeder model W14.

b) Semi-automatic wire feeder with spot timer

W14-20

C) "Hobart" spool gun welding unit model SP9 with CV2 Controller.

d) "Mini-mig" push and pull gun and control.

4.

WELDING CAPACITY

Power Source Capacity is as follows:-

320 Amps,

25

volts,

100%

duty cycle.

-2-

5

SUPPLY

AND

WELDING

CABLES.

Power Sources are suitable for connection to a 415 volt

50

Hertz

3

phase supply.

The recormended fuse size, primary cable

size

and welding

cable

size are

as

follows:-

a)

Fuse

-

l5

amp.

b)

Primary Cable

-

4

core

30/0.25 T.R.S.

c)

Welding Cable

-

1121/0.20

T.R.S.

Q.

SHIELDING

GASES.

a)

Welding

Grade

C02

for all mild and alloy steel welding

in

b)

Argon/CQ2

or

Argon/Oxygen mixtures for all applications

on

thicknesses ranging from

lmrn

upwards.

low

currents requiring

minimum

of

spatter

om

sheet steel and

for stainless steel welding.

of stainless steel.

c)

Argon/Oxygen

and

Argon/C02 mixtures

for

prime quality welding

d)

Argon (pure) for all aluminium welding.

7.

SETTING

W

UNIT

FOR

OPERATION,

a)

General Assembly

of

Packaqed Plant (Refer Drawing

AM511

The Rectifier

Welder

is

shipped

with

the

skids

or

wheels unbolted.

Bolt-

on

the wheel assemblies

with

the steerable

(swivel)

wheels

nearest the front panel and push bar.

If

a "Mini-Boom" wire

feeder mounting

is

supplied, locate the vertical boom

post

in

the special swivel mount at the rear af the machine. Locate

the Wire

Feeder

on the swivel mount, ensuring

that

the fibre

thrust

washer

is

on the pivot pin. Check that the "Wire Feeder"

is

free to swivel

in

all

directions. If necessary apply a

small amount of graphite grease to shaft.

b)

Connection to Mains

Supply.

Note:

This

work

should only

be

done

by

a

qualified electrician.

The power source

is

designed €or connection to

415

volt,

50

hertz,

3

phase supply and the supply voltage

should

be

ascert-

ained before connecting the machine. Access to supply connec-

tion terminals

in

machine may be gained

by

door

in

right

hand

side panel.

Use

a

flexible

4

core primary cable for portable

machines and clamp cable to ensure that there

is

no strain

on

cable connections. The earth

(or

grourd) 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.

-

3-

c) Connection of Cables/Hoses, etc.

With

unit

switched

'OFF'

connect control cable

(6

pin plug)

from power source to wire feeder. Connect gas hose from wire

feeder to gas regulator/flswmeter, ensuring

all

connections

are tightened

firmly.

If

C02

Gas Shield

is

being used, plug

heater into

110

volt socket at rear of

unit.

Next insert gun

cable into socket

of

wire feeder output guide and retain

in

place

with

set screw provided.

Set

screw should not be

tightened

so

as to prevent gun cable

from

swivelling. 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

socket on machine

to

terminal. lug on gun cable. The work lead

("negative") should be .plugged into the

''-I1

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 securedc The wire feeder may be installed remote

from. the power source,

in

which case, extension lead sets com-

prising 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.

3)

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

accord-

ance

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.

0.8m

=

0.030"

0.9m

=

0.035"

1.2m

=

0.045"

The gun cable and gun are normally delivered

with

the

contact

tip and liner spring for wire size nominaked,

but

check that

both are correct size

for

wise being used.

-4-

EELDING

OPERATION

INSTRUCTIONS

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 all welding connections

and plugs for tightness particularly ''work" clamp.

Next ensure that all control cables and

gas

hoses are securely

connected and that Gas Heater

(for

CO2

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

fully

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

suf-

ficient

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

CURREXlT

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 number

of

steps by coarse selector

and fine selector switches. The 'course' selector switch

is

a combined high/low range

ON/OFF

switch working

in

conjunction

with

a "fine" selector switch giving

30

voltage steps.

The foll.awing sequence

of

weld setting

is

recommended:-

a)

Consult

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

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 optim.um tuned welding condition

with

a smooth spatter-free

arc.

-5-

10.

SAFETY

DEVICES

In

the

event

sf

the

power

source becoming overheated the ther-

mostats 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 over-

heating

such

as €an not operating

or

air

flow

restricted.

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

(

II

It

II

'I

1

"

)

11,

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

ary

compressed

air after

6

rmnths' 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)

The wire feed motor/gearbox

is

pre-packed

with

grease and

needs no other lubrication. Change the grease after approximately

14,000

service hours. (see Wire Feeder Instruction Manual).

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 cheeked. 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

import-

ance that the welder wear protective clothing providing suffic-

ient

safety.

-6-

13.

STOPPAGES

AND

THEIR

ELIMINATION

The machine should be checked only

by

a

fully

skilled electrician.

IS

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

L1,

L2

and

L3

on

the

board are correctly connected to

the

m.ains

the

cause

of

the stoppage

must

be sought

in

primary terminal

(voltmeter reading)

the

unit

itself.

The wiring diagram

an

the next pages

will

facilitate

the

location

af

the defect.

WELDING

DATA

TYPICAL

VALUES

Shielding

Gas

is

welding Grade

C02

used

with

a

Gas Preheater.

Contact

Tip

1.5m

inside

of

Gas Nozzle., Wire "Stick

Outt1

6

--

9mmup

to

200

amps.

9

-

12mmover

200

amps.

These Tables are

a

guide only for. initial machine setting and finer adjustments

may

be necessary to achieve optimum welding characteristics for

the

application. Recommended machine setting method

is

to

set

Voltage Switches, Inductance and Gas

Flow

as per Table

then

adjust wire speed

to

obtain recamended current.

TYPICAL

WELD

SETTINGS,

CP.25

-

GAS

:

C02

(10

Eitres/min)

0.9mm

MILD

STEEL

WIRE

Wire Speed Volts

Amps.

L

.

9

(metres/min)

18

.O

50

3.0

I'

17.0

75

3.7

'I

18.0

85

4.1

'I

99.Q

LQO

5.0

It

19.5

120

6.8

It

21.5

150

9.2

23.0

175

12.1

II

I1

25.0

200

L6.8

It

11

32.0

250

11

It

I1

II

11

1,.2fnm

MILD

STEEL

WIRE

Wire Speed Volts

Amps.

2.5

(metres/min)

18.0

100

2.9

18.5

130

3.3

19.0

140

4.0

II

20.0

160

5.3

23.0 200

6.4

23.0

230

8.2

11

28.0

250

10.8

11

It

32.0

280

13.4

32.0

300

P

It

II

It

11

tI

II

li

II

It

NOTE:

Wire speed

is

shown

in

metres/minute and are not dial

calibration settings.

DRAWING

NO.

CP25-03

ISSUE

NO.

4

-

ITEM

NO.

l

2

3

4

5

6

7

8

9

10

11

12

13

14

15

L6

17

L8

L9

20

21

22

23

!4

!5

!6

!7

!8

!9

!O

I1

12

13

14

15

16

-

PART

NO.

CP35-l1

CP25-34

CP15-l4

CP24-0/4

CP24-0/5

CP25-42

CP2-0/9

CP3-62

CP2-0/13

CP3-0/30

CP3-0/35

CP3-0/47

w1-22

w1-23

ZP25-0/18

2P25-03/16

2P2-0/31

c1P25-19

2P35-l2

Y35-13

2P35-14/1

JP35-14/2

3P3 5-

15

UN44

2P35-17

W16

2P25-26

lP35-18

:p35-19

L0029F

'C262

CC262N

L030010

1C40-20/3

:P35-0/37

:P35-0/38

r

DESCRIPTION

Frame

Assembly

Transformer Assembly

Inductance,

Assembly

Fan

Blade

Fan Motor

Rectifier

Assembly

Gas

Heater

Plug

Rectifier Protection

Assembly

Welding Contactor

Ammeter

Shunt

Ammeter

0-400

Amps.

Voltmeter

0

-

60

Volt

Indicator Light

Fuse

Holders

Fine Selector Switch

Coarse

Selector Switch

Control

Plug

Front Panel

Back Panel

Top

Cover

Left

Hand Side

Cover

Right Hand

Side

Cover

Zontactor and Switch

Baffle

Plate

Type

No.

Serial

No.

Plate

Terminal Assembly

Iutput Terminals

Fransformer Support

Pie

Bar

?an Mounting Bracket

3ye

Nut

;as

Outlet Fitting

Jut

for

Above

3/4"W

x

3"

Hex.

HD.

Set

Screw.

3akelite

Insulators

Loom

Assembly

;as

Hose

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WIA Weldmatic 320 Owner's manual

WIA Weldmatic 320 Owner's manual

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