WIA Weldmatic 400 Owner's manual

WELDMATIC

400

MODEL NO. CP4

"""""

CAT.

7524/4

.6/80

FROP4 SERIAL NO.

40043

"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 NO.

OF THE MACHINE AND THE PART NO. OF THE

ITEM

REQUIRED. FAILURE

TO

SUPPLY THIS 1NFOF.MATION

WILL

RESULT IN UNNECESSARY DELAYS

IN SUPPLYING THE CORRECT PARTS.

WELDING INDUSTRIES OF AUSTRALIA PTY. LTD.

Melbourne

429 4766

Sydney

60.7

2655

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

400 (CP4)

INTRODUCTION

GENERAL

This

manual has been

prepared

especially for use

in

familiar-

izing personnel with the design, installation, operation,

maintenance, and

troubleshooting

of

this

equipment.

All

information

presented

herein should

be

given careful consid-

eration to assure optimum performance of this equipment.

RECEIVING/HANDLING.

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

loses

or

damage that may have occurred in transit must

be

filed by

the

purchaser

with

Welding Industries

of

AustraJia 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

improper

..

-

welding

applications.

CONTENTS

General Description

Setting up

for

Operation

PAGE

NO.

1

2-3

Welding

Operation

Instructions 4

Maintenance Instructions

5-6

Welding

Data

-

Table

'IC"

7

-

Parts

List

CP4-02 Issue 4

8

-

Assembly Drawing CP4-02 Issue

2.

9

Circuit

Diagrams

-

CP4

-

C9

10

Mobile

Kit

Assembly

-

AM116

Safety

Practices

Guarantee Card

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"

Plants consists of three basic

units:-

1.

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 trans-

portation. For

units

with

wheel mounting four solid rubber

tyred wheels are provided: the two front wheels are steerable

permitting easy movement

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, fine

voltage selection switch, power

ON/OFF

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 induc-

tance

unit

providing the "inductance" or degree

of

slope neces-

sary 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

I

Gas metal arc welding

within

the capacity of the power source

can be carried out

with

the

following

equipment:-

a)

Semi-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:-

400

Amps,

42

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 recommended fuse size, primary

cable

size and welding

cable

size

are

as

follows:-

a)

Fuse

-

35

amp.

b)

Primary

Cable

-

4

core

56/0.30

T.R.S.

c)

Welding

Cable

-

703/0.30

T.R.S.

SHIELDING

GASES.

Welding Grade

C02

for

all

mild

and alloy

steel

welding in

thicknesses ranging

from

lmm

upwards.

Argon/COZ

or

Argon/Oxygen mixtures for

all

applications on

low

currents requiring minimum

of

spatter

on sheet

steel

and

for

stainless

steel

welding.

Argon/Oxygen and Argon/C02 mixtures

for

prime quality

weld-

ing

of

stainless

steel.

Argon (pure) for

all

alum.inium welding.

SETTING

UP

UNIT

FOR

OPERATION.

General

Assembly

of Packaqed Plant

(Refer

Drawing

Apqjjs)

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

of

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

a11

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

for

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 m.ay

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

ground) connection (green/

yellow) must

be

securely fastened

to

the 'earth' terminal on

the m.achine adjacent

to

the supply connection

terminals.

CAUTION

Before

inserting primary

cable

plug in m.ains 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

plug)

from power source to wire feeder. Connect gas

hose

from wire

feeder

to

gas regulator/flowmeter, 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 tight-

ened

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

II+II

socket on machine to terminal lug

on

gun cable. The work

lead ("negative") should be plugged !into the

'I-''

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 secured. The wire feeder may be inst-

alled remote from the power source,

in

which case, extension

lead sets comprising 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.

e)

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

quides.

0.8m

=

0.030"

l

.6mm

=

1/16"

0.9m

=

0.035" 2.4m

=

3/32"

1.2m

=

0.045"

3.2mm

=

1/8"

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.

-4-

WELDING

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 a11 welding lead

plugs are inserted

in

the correct polarity sockets

-

electrode

"positive"

,

work "negative"

.

Check

all

welding connections

and plugs for tightness particuarly "work" clamp.

Next ensure that all control cables and gas hoses are securely

connected and that

Gas

Heater (for

C02

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 .Elow

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 sufficient

to prevent any llslip'l 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

CURRENT,

VOLTAGE

AND

INDUCTANCE.

The welding current

is

determined automatically by "Wire Speed".

The electrode wire

is

fed at the pre-selected speed by the 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,

as

will

be indicated by the ammeter. The output voltage of the power

source, indicated

by

the voltmeter when the gun switch

is

closed,

is

divided

into

a number of steps

by

Coarse Selector

and Fine Selector switches. The

CP4

has Coarse Voltage and

Fine Voltage switches each

with

six steps giving

36

voltage

setting for the machine.

The inductance terminal sockets are numbered

"1

-

4".

Depending on the type

of

welding conditions various inductance

values are required, The typical weld setting chart indicates

the recommended sockets for various welding mnditions.

As

a

general rule, low welding currents require inductance

No.1

or

2.

For aluminium and tubular flux cored wire, Inductance Socket No.1

is

used exclusively.

The following sequence of weld setting

is

recommended:-

a> Consult typical weld setting chart.

-5-

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 optimum tuned welding condition

with

a sm.ooth spatter-free

arc.

10.

.

SAFETY

DEVICES

In

the event of the power source becom.ing 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 fan 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

(

'I

l'

'.

.

>

Fuse

E3

-

5

amps

(

I'

1

Fuse

E4

-

5

amps

(

'I It

)

11.

YINTENANCE

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) 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

com-

pressed air.

-6-

cl

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. 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,

13. STOPPAGES

AND

THEIR

ELIMINATION

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

three terminals

L1,

L2

and L3 on the primary terminal

board

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

-7-

WELDING

DATA

-

TYPICAL

VALUES

Shielding Gas

is

welding Grade

C02

used

with

a

Gas Preheater.

Contact Tip

1,Sm

inside of Gas Nozzle, Wire "Stick

Out"

6

-

9mm

up

to

200

amps.

L2

-

19m.

over

200

amps. These Tables

are

a

guide only for initial machine setting

and

finer adjust-

ments may be necessary to achieve optimum. welding character-

istics

for the application. Recommended machine setting method

is

to set Voltage §witches, Inductance and Gas Flow

as

per

Table then adjust wire speed to obtain recommended current.

Rect-

ifier

CP4

Wire Gas

Size

1.2msn.

C02

(Solid

10

Lit./

Wire)

Min.

15

Lit./

Min.

1.6mm

(Solid

wire)

1.6mrn

I15

Lit./

Wire

Speed

Metres

Per

Min

2.2

2.6

3.3

5.7

7.5

9.2

6.4

7.0

8.2

7.2

9.2

12.0

v

01

Coarse

2

3

4

5

6

5

6

S

Fine

I

2

3

5

l.

1

6

4

6

3

6

2

Induc-

tance

1

2

3

4

1

Amps

.

Volts

110

18

130

18.5

160

19

200

23

240

26

280

30

300

33

360

38

400 42

300

30

350

32

400 34

Wire speed

is

shown

in

metres/minute and are not dial

calibration settings.

-

ITEM

ALL

2

2.1

2.2

2.3

3

3.1

3.2

3.3

4

4.1

4.2

5

8

9

18

21

22

24

25

26

26.1

27

28

29

30

32

33

34

37

37.1

37.2

38

39

-8-

DRAWING

NO.

CP4-02

-

SPARE PARTS LIST ISSUE

6

PART

NO.

CP4-32

CP15-13/2

CP15-13/3

CP3-9/8

CP4-8

CP4-19/1

CP4-19/2

CP4-19/3

CP4-2

CP4-7/1

CP4-7/2

CP25-0/7

CP3-0/4

MC35-0/6

CP15-0/7

CP4-16

CP5-0/19

AM16

CP15-0/14

TC262

TC262N

CP3-0/47

CP5-0/16

w1-22

CP5-0/17

CP5-0/13

CP5-0/14

CP5-0/15

W1-23

K10

K11

CP32-5

CP22-2/13

DESCRIPTION

RECTIFIER ASSEMBLY

DIODE

(R)

THERMOSTAT

TRANSFORMER ASSEMBLY

R.

H.

PRIMARY/SEC

.

COIL

CENTRE PRIMARY/SEC. COIL

L.H. PRIMARY/SEC. COIL

INDUCTANCE ASSEMBLY

LEFT

HAND

INDUCTANCE COIL

RIGHT

HAND

INDUCTANCE COIL

CONTROL TRANSFORMER

FAN

BLADE

FAN

MOTOR

GAS

HEATER PLUG SOCKET

RECTIFIER PROTECTION ASSEMBLY

WELDING CONTACTOR

OUTPUT TERMINALS

CONTROL PLUG

GAS

NIPPLE

GAS

NIPPLE NUT

VOLTMETER 0-60V

AMMETER 0-600A

INDICATOR LIGHT

AMMETER SHUNT 0-600A

POWER

ON/OFF

SWITCH

COARSE VOLTAGE SWITCH

FINE VOLTAGE SWITCH

FUSE HOLDER

3AG.

3A. DELAY FUSE

3AG.

5A.

DELAY FUSE

RESISTOR

STAND

OFF

INSULATOR

-@

"0

-0

"@

"-1

B=&--

8"

I

-0

4-

3

l

-0

@-

-8

;1

P

A

41

0

SAFE

PRACTICES

IN

USING

WELDING

EQUIPMENT

Produced by Welding Industries of Australia

Pty.

Ltd. in the interests of

improving operator safety. These notes 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, Departments of Labour and Industry

or

Mines Depart-

ment and other Local Health or Safety Inspection Authorities may have

additional requirements.

1.

A

neat

uncluttered work area

makes

for safe working habits.

2.

Burn Prevention

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. Skin burns

resemble

acute sunburn, those from gas-shielded

arcs

are

mre

severe and painful.

Wear

protective clothing

-

leather (or asbestos) gauntlet gloves, hat, and

safety-toe boots. Button shirt

collar

and pocket flaps, and

wear

cuffless

trousers to avoid entry of sparks and slag.

NEVER

LOOK

AT

AN

ARC

WITHOUT

PROTECTION.

Wear

helmet with safety goggles or glasses with side shields underneath,

appropriate filter lenses or plates (protected by clear cover glass). This

is

a

MUST for welding

or

cutting, (and chipping) to protect the eyes from

radiant energy and flying

metal.

Replace cover glass when broken, pitted,or

spattered.

Avoid oily or greasy clothing.

A

spark may ignite them. Hot metal such

as

electrode

stubs

and workpieces should

never

he 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 work overhead.

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

or

cut.

3.

Toxic Fume Prevention

Adequate ventilation

is

essential. Severe discomfort, illness or death can

result

from fumes, vapors, heat,

or

oxygen enrichment or depletion that welding

(or cutting) may produce. Prevent them with adequate ventilation.

NEVER

ventilate with oxygen.

Lead, cadium, 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.

Vapors 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 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 minute

amounts

of

trichlorethylene or percholorethylene.

4.

Fire and Explosion Prevention

Causes of fire and explosion are:- Combustibles reached by the arc, flame, fly-

ing sparks, hot slag, or heated material; misuse

of

compressed gases and cylin-

ders; and short circuits.

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 goggled operator. Sparks and slag can fly

10

metres.

To

prevent fires and explosions:- Keep equipment cl.ean and operable, free of

oil, grease, and

(in

electrical parts) of metallic particles that can cause short

circuits.

If combustibles are

in

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 mved, 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 pr'otected by heat-resistant covers

or shields.

Fire watcher

must

be standing by with suitable fire extinguishing equipment

during and for some time after welding or cutting if:

(1)

combustibles (including building construction) are within

LO

metres.

(11)

combustibles are further than

10

metres but can be ignited by sparks.

(111)

openings (concealed or visible)

in

floors or

walls

within

l0 metres

(1V)

combustibles adjacent to walls, ceilings, roofs, or metal partitions

may expose combustibles to sparks.

can be ignited by radiant or conducted heat.

After work

is

done, check that area

is

free of sparks, glowing embers, and flames.

An

empty container that. held combustibles,

or

can produce flamable vapors when

heated, must never be welded on or cut, unless container 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 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

AS.1674-1974.

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 vapors such as petrol).

5.

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 con-

ductor. 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.

6.

Electrode Holders and Connectors

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.

7.

Terminals

Terminals and other exposed parts of electrical

units

should have insulated knobs or

covers secured before operation.

-

ITEM

NO.

2

2.1

2.2

2.3

3

3.1

3.2

3.3

4

4.1

4.2

5

8

9

18

21

22

24

25

26

26.1

27

28

29

30

32

33

34

37

38

39

-8-

DRAWING NO. CP4-02

-

SPARE PARTS

LIST

ISSUE

4.

PART NO.

CP6-5

CP6-5/2

CP6-5/3

CP3-9/8

CP4-8

CP4-19/1

CP4-19/2

CP4-

19/3

CP4-2

CP4-

7/1

CP4-7/2

CP25-0/7

CP3-0/4

MC35-0/6

CP2-0/9

CP4-16

CP5-0/19

AM1

6

CP2-0/31

TC262

TC262N

CP3-0/47

CP5-0/16

w1-22

CP5-0/17

CP5-0/13

CP5-0/14

CP5-0/15

W1-23

CP32-5

CP22-3/13

DESCRIPTION

RECTIFIER ASSEMBLY

DIODE

DIODE (R)

THERMOSTAT

TRANSFORMER ASSEMBLY

R.H.

PRIMARY/SEC.

COIL

CENTRE

PRIMARY/SEC.

COIL

L

.H.

PRIMARY/SEC.

COIL

INDUCTANCE ASSEMBLY

LEFT

HAND

INDUCTANCE COIL

RIGHT HAND INDUCTANCE COIL

CONTROL TRANSFORMER

FAN BLADE

FAN MOTOR

GAS HEATER PLUG SOCKET

RECTIFIER PROTECTION ASSEME3LY

WELDING CONTACTOR

OUTPUT TERMINALS

CONTROL PLUG

GAS NIPPLE

GAS NIPPLE NUT

VOLTMETER 0-60V.

AMMETER 0-600A.

INDICATOR LIGHT

AMMETER SHUNT 0-600A.

POWER ON/OFF SWITCH

COARSE VOLTAGE SWITCH

FINE VOLTAGE SWITCH

FUSE HOLDER

RESISTOR

STAND OFF INSULATOR

L

-

ITEM

NO.

I

2

2.1

2.2

2.3

3

3.1

3.2

3.3

4

4.1

4.2

5

8

9

18

21

22

24

25

26

26.1

27

28

29

30

32

33

34

37

37.1

37.2

38

39

-8-

-

DRAWING

NO.

CP4-02

-

SPARE PARTS LIST ISSUE 5.

PART

NO.

CP4-32

CP15-13/2

CP15-13/3

CP3-9/8

CP4-8

CP4-19/1

CP4-19/2

CP4-19/3

CP4-2

CP4-7/1

CP4-7/2

CP25-0/7

CP3-0/4

MC35-0/6

.

CP2-0/9

CP4-l6

CP5-0/19

AM16

CP2-0/31

rc262

TC2 6 2N

ZP3-0/47

2P5-0/16

$1-

2

2P5-0/17

2P5-O/E3

2P5-0/14

2P5-0/15

41-23

x10

CP32-5

CP22-2/13

DESCRIPTION

RECTIFIER ASSEMBLY

DIODE

(R)

THERMOSTAT

TRANSFORMER ASSEMBLY

R.H.

PRIMARY/SEC. COIL

CENTRE PRIMARY/SEC. COIL

L.

H.

PRIMARY/SEC

.

COIL

INDUCTANCE ASSEMBLY

LEFT

HAND

INDUCTANCE COIL

RIGHT

HAND

INDUCTANCE COIL

CONTROL TRANSFORMER

FAN

BLADE

FAN

MOTOR

GAS

HEATER PLUG SOCKET

RECTIFIER PROTECTION ASSEMBLY

WELDING CONTACTOR

OUTPUT TERMINALS

CONTROL PLUG

GAS

NIPPLE

GAS

NIPPLE NUT

VOLTMETER 0-60V

AMMETER 0-600A

INDICATOR LIGHT

AMMETER SHUNT 0-600A

POWER

ON/OFF

SWITCH

COARSE VOLTAGE SWITCH

FINE VOLTAGE SWITCH

FUSE HOLDER

3AG.

3A.

DELAY FUSE

3AG.

5A.

DELAY FUSE

RESISTOR

STAND

OFF

INSULATOR

l

r

k

P

l

1

/

I

ll

i

.

0

U

W'

-0

-8

n

WIA Weldmatic 400 Owner's manual

WIA Weldmatic 400 Owner's manual

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