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
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
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
11
28.0
250
10.8
11
It
32.0
280
13.4
32.0
300
P
It
II
II
It
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
Page is loading ...
Page is loading ...
Page is loading ...
/