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
pin
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
2
2
3
4
5
5
6
6
5
5
6
S
Fine
I
2
3
5
5
l.
1
6
4
6
3
6
2
Induc-
tance
1
1
1
2
2
3
4
4
4
1
1
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
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
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
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
/