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WELDING INDUSTRIES
OF
AUSTRALIA
A
DIVISION
OF
WELDING
INDUSTRIES
LIMITED
ACN
004
547
l1
1
Head Office and International Sales
5
Allan
Street, Melrose
Park
South
Australia,
5039
South
Australia, 5039
Telephone (08) 8276 6494 Facsimile
(08)
8276 6327
www.weldingindustries.com.au
OWNERS MANUAL
UTILITY CV1
3
MODEL UTCVI
3-0
05/98
QUALITY WELDING
PRODUCTS,
SYSTEMS AND SERVICE
(
The information contained
in
this manual has been prepared
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
of
the
machine and
part
number of the item required.
A11
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.
SAFETY
Before this equipment is
put
into operation, the Safe Practices section
at
the back
of this manual must
be
read completely. This
will
help
to
avoid possible injury due
to
misuse or improper welding applications.
CONTENTS
l
..........................
Introduction
....................................................
3
2
..........................
Receiving..
.....................................................
3
3
..........................
Specifications
................................................
4
4
..........................
Power Source Controls
..................................
5
5
..........................
Connection
to
Mains Supply
..........................
6
6
..........................
Welding Polarity Selection
............................
6
7
..........................
Shielding Gas
................................................
6
8
..........................
Fitting Electrode Wire
....................................
7
9
..........................
Establishing
a
Weld Setting
..........................
7
10
........................
Duty Cycle
.....................................................
9
11
........................
General Maintenance
....................................
9
12
........................
Fault Finding
..................................................
IQ
l3
........................
Circuit Diagram
..............................................
l
l
14
........................
Parts Diagram
................................................
12
15
........................
Parts List
........................................................
l3
16
........................
Safe Practices Information
.............................
l4
QUALITY WELDING
PRODUCTS,
SYSTEMS AND
SERVICES
UTILITY
CV13
OWNERS
MANUAL
"
"
l.
INTRODUCTION
The UTILITY
CV13
is
a
Gas Metal Arc power source designed for gas shielded
welding using solid electrode wires, and self shielding
flux
cored wires. The consumable
wire is fed to the welding gun by motor driven drive rollers. The arc is struck between the
work piece and the end of the wire, which melts
to
form the weld deposit.
With solid consumable wires, the arc is protected by an envelope of shielding gas
supplied via the gun from
a
separate
gas
cylinder.
"Self shielding" wires contain a core of flux which, during welding, generates gases
to
shield the arc and the weld pool. The flux also leaves
a
light protective slag over the
cooling weld deposit.
In
this way a separate gas supply is not required.
The
UTILITY
CV13 is intended for
use
with
0.6mm
and Q.8mm solid wires, and
0.8
and 0.9mm cored wires. Smaller wire sizes are recommended for welding at lower
currents such as thin sheet-metal applications. Increasing the wire diameter permits
thicker gauges
to
be welded. The UTILITY CV1
3
will accept
l
kg and 5kg spool types of
electrode wire.
2.
RECEIVING
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
UTILITY
CV13
package
contains:
UTILITY
CV13
Power Source
Fitted welding torch
Work lead and clamp
Mobile mounting kit (wheels, handle and front prop)
Spare welding tips
(3
)
R
Gas hose connector
(This) Owners Manual
Optional items:
Gas regulator (Argon)
......................................................
GW251190
Consumable wires
to
suit the
UTILITY
CV13:
Carbon steel solid wire O.6mm, 0.9
kg
............................
ES606BP
Carbon steel solid wire 0.8mm, 8.9
kg
............................
ES608BP
E
Carbon steel solid wire 0.6mm, 5kg
................................
ES606M
Carbon steel solid wire 0.8mm, 5kg
................................
ES608M
Carbon steel self-shielding wire 0.9mm,
8.9
kg
...............
H021
BO91
KG
Carbon steel self-shielding wire 0.9mm,
5
kg
..................
H021
B09M
QUALITY
WELDING
PRODUCTS,
SYSTEMS
AND
SERVICES
L
UTILITY
CV13
OWNERS MANUAL
3.
SPECIFICATIQNS
Model Number
.........................................................................
UT~Vl3-0
Primary Supply
..................................
240
Volts AC Single Phase,
50
Hz
Rated Input current.
....................................................................
IO
Amps
Supply Flexible Cable
.....
10
Amps, type
Y
attachment (see note below)
Maximum Rated
Input
Current..
..............................................
.l53
Amps
Open Circuit Voltage
.....................................................
57
Volts DC
(pk)
Rated Output
...........................................
100 Amps, l9 Volts,
25%
Duty
Degree
of
Protection
........................................................................
IP22
Electrical Approvals Number..
.........................................
.S1221
/UTCV13
NOT]
If the supply flexible cable is damaged, it must be replaced by the manufacturer or
it's service
agent
or similarly qualified person in order
to
avoid
a
hazard.
QUALlTY
WELDING
PRODUCTS,
SYSTEMS
AND
SERVlCES
UTILITY
CV13
OWNERS
MANUAL
Page
5
4. POWER SOURCE
CONTROLS
WIRESPEED
CONTROL
VOLTAGE
CONTROL
SWITCHES
POWER
SWITCH
NEGATIVE
OUTPUT
TERMINAL
POSITIVE
OUTPUT
TERMINAL
POWER ON/OFF SWITCH
A rocker type switch is located on the front panel. Select the ON position to
energise the power source.
An indicator lamp within the on/off switch is lit when the machine
is
energised.
WIRESPEED CONTROL
This control is used to set the feeding rate
of
the consumable electrode wire.
Rotating the dial clockwise increases the wirespeed,
so
increasing the welding
current.
An increase of wirespeed will usually require an increase
of
welding voltage to
maintain stable welding conditions.
VOLTAGE CONTROLS
The three voltage control switches together provide
6
steps
of
welding voltage
adjustment, arranged as
3
steps in
LO
range, and
3
steps in
HI
range.
For voltage steps
2
and
3,
also select position A.
OUTPUT TERMINALS
The welding output current is available on these terminals. Refer to Section
6
for
information regarding the correct connection of the welding leads.
QUALITY WELDING PRODUCTS,
SYSTEMS
AND SERVICES
Paae
B
UTILITY
CV13
OWNERS
MANUAL
5.
CONNECTION
TO
ELECTRICAL MAIMS POWER SUPPLY
The
UTILITY
CV1
3
is fitted with a
10
Amp mains power supply cable, and is
suitable for connection to a standard domestic
10
Amp power outlet.
If the machine is
to
be used
in
conjunction with an extension power cable, the
cable must be of sufficient capacity to avoid excessive voltage drop, which could limit
the output capacity of the welder.
The rated input current of the
UTILITY
CV1
3
is
10
Amps, and
so
a fuse or
circuit breaker rated
at
20
Amps may be installed
to
avoid nuisance tripping.
6.
WELDING
POLARITY
SELECTION
POSITIVE
GUN
welding gun Positive
(+)
polarity, and the work piece Negative
(-)
polarity.
the photograph on page
5.
NEGATIVE
GUN
welding gun Negative
(-)
polarity, and the work piece Positive
(c)
polarity.
terminal, and the Gun lead to the
(-)
terminal.
7.
SHIELDING
GAS
Gas shielded Mig welding with a solid consumable wire is carried out with the
To set the machine for this condition, connect the Gun and Work leads as shown
in
Mig welding with
a
self shielded flux cored consumable wire is carried out with the
To
set the machine for this condition, connect the Work lead
to
the
(+)
output
When welding using solid consumables wires, a shielding gas is required
to
protect
the arc and molten weld
pool
from the effects of atmospheric gases.
A
suitable gas
pressure regulator
/
flow gauge must be fitted
to
the
gas
cylinder, and the
CV13
gas
supply hose connected to the regulator.
The choice of shielding gas type is determined by the application, and the welding
consumable to be used.
In
general the following applies, consult your gas supplier for
more specific information.
Carbon Steel
.................................
Argon
+
5
to
18%
CO2
E
Aluminium
......................................
100%
Argon
.
Stainless Steel
..............................
Argon
+
1
to
2%
Oxygen
Set the gas regulator for
a
flow
rate of
IO
to
15
litreslmin. In windy or outside
locations it may be necessary to increase this setting to avoid weld porosity resulting
from insufficient gas coverage.
QUALlTY
WELDlNG
PRODUCTS,
SYSTEMS
AND
SERVIES
UTILITY
CV13 OWNERS
MANUAL
Page
7
8.
FITTING
THE
ELECTRODE WIRE
PRESSURE
SPRING
.I__r
,,.
,.
PRESSURE
ROLL
ARM
DRIVE
Place the spool
of
electrode wire onto the spool holder. Replace the wing nut, and
tighten sufficiently to apply some braking force on the wire
spool.
Both
1
kg and
5
kg spools can be fitted.
allowing the upper pressure roll arm to be lifted away from the lower drive roll.
Open the wire drive mechanism by rotating the pressure spring outwards,
Check that the drive roller groove is correct for the wire in use. The drive roller
has two groove sizes, refit as required to select the appropriate groove.
Check also that the appropriate size tip is fitted to the welding gun, replace if
necessary.
Straighten a short length of the consumable wire, and pass it through the inlet
Close the pressure arm and spring mechanism, check that the consumable wire
guide, over the driven roller and into the gun wire guide.
is seated in the drive roller groove.
With the machine power on, close the gun switch to feed wire to the gun.
Adjust the compression of the spring assembly to just provide sufficient clamping
of the drive rolls to achieve constant wirefeed.
Do
not over tighten as the
consumable wire can be damaged leading to erratic wirefeed.
9.
ESTABLISHING A WELD SETTING
Page
8
UTILITY
CW3
OWNERS
-
MANUAL
WELDING
RESULT
The welding current should be established 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 application.
‘GOOD’
WELD
‘BAD‘ WELD
A
‘good’
weld will have the Characteristics illustrated above. The weld
has
penetrated into the parent metal, fusing the root of the weld where the two plates meet,
and the weld blends smoothly into the side walls.
The characteristics of a
‘bad’
weld are also shown above. Here the weld has not
penetrated the root joint, and there is poor side wall fusion.
This
lack of fusion would
normally be corrected by increasing the arc voltage, or increasing both wirespeed and
voltage to achieve a higher welding current.
GUN
POSITION
For ‘down hand’ fillet welding with gas shielded solid wire consumables, the gun is
normally positioned as
in
the figures below, with the nozzle pointing
in
the direction of
travel.
If
using self shielded
wires,
the gun is
normally
positioned with the
nozzle
pointing
away from the direction of travel, referred to as ‘dragging’ the weld. Self shielded wires
should be operated with approximately
15mm
of wire ‘stick-out’ from the end of the
contact tip,
GAS-SHIELDED WIRE
SELF-SHIELDED WIRE
QUALITY WELDING PRODUCTS,
SYSTEMS
AND
SERVICES
IO.
DUTY
CYCLE
The term ‘duty cycle’ indicates the percentage welding time available from the
equipment when operating at the rated output current.
The UTILITY
CV13
is rated at
100
Amps,
‘l9
Volts,
25%
duty cycle. If the machine
is operated at
a
lower welding current, greater duty cycle percentage is available.
The machine is protected by in-built temperature protection devices. These will trip
if the machine is operated
in
excess of its current and duty cycle rating, preventing
damage to internal components. If this occurs, an indicator light on the front panel will
be lit, and the machine will not deliver welding current until it has cooled sufficiently.
1
l.
GENERAL,
MAINTENANCE
DUST
BUILD-UP
Excessive dust
build
up can reduce the effectiveness of the internal cooling fan,
leading to reduced operating duty cycle. It is recommended that at regular intervals,
according to the prevailing conditions, the machine covers be removed and any
accumulated dust be removed using dry, low pressure compressed air.
Ensure that the internal Earth wire
is
reconnected to the cover before the cover is
refitted.
Inspect the visible components for any signs of overheating or other damage.
Report any observed problems to qualified service personnel.
WIREFEED
In Mig welding, satisfactory welding results can only be obtained when the wirefeed
to the welding gun is smooth and constant. It is important to regularly monitor the
following points;
Keep the gun cable wire guide clear of dust and swarf build-up. Accumulated dust
may
be partially cleared by purging the wire guide with compressed air, however it will
require occasional replacement.
Replace the welding tip as it becomes worn or damaged. Welding current is
transferred to the wire at the tip, and any tendency to poor contact will affect welding
results.
Keep.the wirefeeding mechanism clean. Periodically check the drive roller groove
for wear
or
clogging, and replace the
roller
when necessary.
QUALITY
WELDING
PRODUCTS,
SYSTEMS
AND
SERVICES
L
UTILITY
CV13
OWNERS
MANUAL
Paae
9
LLAL
Pa e10
-
112.
FAULT
FINDING
NO
WELDING CURRENT
Check that mains supply
is
available at the Power Source, ie. that the fan is
running and the
POWER
ON
indicator is lit.
Check for co.ntinuity of the welding current circuit, ie. work lead, work damp and
electrode holder: Check that the electrode and work leads are correctly connected for
the welding process in use.
The welding power source incorporates in built thermal protection devices which
will trip if the unit is used in excess
sf
its duty cycle. In this event, the machine will not
deliver welding current, and the front panel Over temperature indicator will be lit. Leave
the machine energised with the fan running to achieve the maximum cooling rate.
If equipment failure is suspected, forward the unit to your nearest
WIA
Sales and
Service Branch or qualified service agent.
UNSATISFACTORY WELDING
RESULTS
The most frequent cause
sf
erratic welding conditions
is
poor wirefeeding. Check
the condition
of
the gun cable liner, the drive roller
and
groove,
and the welding tip.
Replace worn or damaged items.
WELDING
CIRCUIT
Ensure that the work clamp
is
securely tightened onto the work-piece
so
that
good electrical contact is achieved.
Surface contamination
of
the work piece by water, oil, grease, galvanising, paint,
or oxide layers can severely disturb the welding are resulting in
a
poor weld. Best
results will be obtained if the surface is clean and
dry.
WIREFEED
I
ARC
VOLTAGE RELATIONSHIP
If the consumable wire is stubbing into the work piece and
a
steady arc cannot be
obtained, it is likely that the wirespeed
is
set too high to suit the welding voltage. To
correct this situation, decrease the wirespeed setting. If the arc length is
too
long,
increase wirespeed setting.
L
UTILITY
CV13
OWNERS MANUAL
Page
l
l
QUALITY
WELDlNG PRODUCTS,
SYSTEMS
AND
SERVlCES
Paae
12
UTILITY
CV13
OWNERS MANUAL
’14.
PARTS
DIAGRAM
l”
SIDE COVERS. HANDLE AND LEADS OMITTED FROM THESE VIEWS
SIUE
COVER OMITTED FROM THIS VIEW
QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICES
-
UTILITY
CV13
-
OWNERS
MANUAL
Page-
115.
PARTS
LIST
Item
Part
Number
Descriptiom
1
.......................
E21 62501
3..
.................
Wheel
2
.......................
E21690012
...................
Spool holder retaining ring
3
.......................
E21690011
...................
Fixed spool holder
4
.......................
E33805001
...................
Wire feed drive roll
0.6
/
0.8mm
5
.......................
SA32-0/1
......................
Plug
6
.......................
SA14 0-0/2
....................
Socket
7
.......................
E230Q0040
...................
Porch complete
9a
.....................
WGUYI
........................
Welding tip 06mm
9b.
....................
WGUY2
........................
Welding tip Q.8mm
9c
.....................
WGUY3
........................
Welding tip 0.9
/
l
.Omm
10.
....................
WGUY4
........................
Gas nozzle
1
l
.....................
WGWVCI
..............
work
clamp
12..
...................
S1 40-011
.......................
Handle
13
.....................
E44400002
...................
Wirefeed mechanism
14
.....................
E22810002
...................
Wire feed motor
15
.....................
E2271 001
5
...................
Wirefeed printed circuit board
16..
...................
UPCVl3-0/2
.................
On/off switch cover
17
.....................
E22200Q23
...................
On/off switch with light
18..
...................
E441 28032
...................
Welding transformer UTCVI 3
19
.....................
E2221
0013
...................
Rectifier thermostat 8OoC
20
.....................
E22800010
...................
Fan motor and blade
21
.....................
E22210016
...................
Transformer thermostat 127OC
22..
...................
E3372501
5..
.................
Handle extension
23
.....................
hlTCVl3-0/1
.................
Mains cable
l
OAmp
25
.....................
E22400038
...................
Welding rectifier
27
.....................
UTCVI 3-0/3
.................
Welding voltage selection switch cover (3)
28
.....................
E22200006
...................
Welding voltage switch (3)
32
.....................
E21800036
...................
Spool holder knob
33
.....................
E33800004
...................
Spool
retainer spring
24..
...................
E441 3500.4
...................
Welding inductance UTGVI 3
26
.....................
E21690018
...................
Wirespeed knob
29
.....................
E21690001
...................
Panel grommet
34
.....................
E21600006
...................
Handle Grip
QUALlTY
WELDiNG
PRODUCTS,
SYSTEMS
AND
SERVICES
g
MANUAL
96.
SAFE PRACTICES
tN
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 available
from the Standards Association of Australia, also various State Electricity Authorities, Bepartments of
Labour and Industry or Mines Department and other Local Health or Safety Inspection Authorities may
have additional requirements. WIA Technical Note TN7-98 also provides a comprehensive guide
to
safe
practices in welding.
EYE PROTECTION
NEVER
LOOK
AT AN ARC WITHOUT PROTECTION. Wear a helmet with safety goggles or
glasses with side shields underneath, with appropriate filter lenses protected by clear cover lens. This
is
a
MUST for welding, cutting, and chipping to protect the eyes from radiant energy and flying metal. Replace
the cover lens when broken, pitted, or spattered.
Recommended
shade filter
lens.
Amps
TIG
MMAW
MIG
Pulsed
MIG
Q-100
............
10
.................
9
...................
10
.................
12-13
100-150
.........
11
.................
10
.................
10
.................
12-13
150-200
.........
12
.................
10-11
............
11-12
............
12-13
200-300
.........
13
.................
11
.................
12-13
............
12-1
3
300400
.........
14
.................
12
.................
13
.................
14
400400
............................
I_
13
.................
14
.................
14
500
+
..................................................
" "
t4
.................
14
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 work
pieces should never be handled without gloves.
Ear plugs should be worn when wetding 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
FUMES.
Adequate ventilation with air is essential. Severe discomfort, illness or death can result from fumes,
vapours, heat, or oxygen depletion that welding or cutting may produce. NEVER ventilate with oxygen.
Lead, cadmium, 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 beryllium, 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 air-
supplied 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 irritating products. The ultra-violet (radiant) energy of
the arc can also decompose trichlorethylene and perchlorethylene vapours
to
form phosgene.
Bo
not weld
or cut where solvent vapours can be drawn into the welding or cutting atmosphere or where the radiant
energy can penetrate
to
atmospheres containing even minute amounts
of
trichlorethylene or
perchlorethylene.
QUALITY
WELDlNG
PRODUCTS, SYSTEMS AND SERVICES
L
UTILITY
CV13
OWNERS
MANUAL
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 dean 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
10
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 fire extinguishing equipment
during and for some time after welding or cutting if;
-
Combustibles (including building construction) are within
IO
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
to
sparks.
-
Combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or
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 vapours when heated.
Such a container must never be welded on or cut, unless it has first been cleaned as described in
AS1674-1974, the
S.A.A.
Cutting and Welding Safety Code. This includes a thorough steam or caustic
cleaning (or a solvent or water washing, depending
on
the combustible's solubility), followed by purging
and inerting with nitrogen or carbon dioxide, and using protective equipment as recommended in AS1674-
1974.
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
equipment 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.
Do
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 must have insulated knobs or covers secured
before operation.
QUALITY
WELDING
PRODUCTS, SYSTEMS
AND
SfZRVlCES
/