WELDMATIC 250

MODEL NO. CP25

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CAT. 7523/25

9/80

FROM SERIAL NO. 2539-'l

THE INFORMATION CONTAINED I N THE FOLDER I S SET OUT TO ENABLE YOU TO PROPERLY MAINTAIN YOUR NEW EQUIPMENT AND ENSURE THAT YOU OBTAIN M A X I M U M OPEFWTING EFFICIENCY.

PLEASE ENSURE THAT THIS FOLDER I S KEPT I N A SAFE PLACE FOR READY REFERENCE WHEN REQUIRED.

WHEN REQUESTING SPARE PARTS, QUOTE THE MODEL N o . AND SERIAL N o . O F THE MACHINE AND THE PART N o . O F THE ITEM REQUIRED. FAILURE TO SUPPLY THIS INFORMATION WILL RESULT I N UNNECESSARY DELAYS I N SUPPLYING THE CORRECT PARTS.

WELDING INDUSTRIES O F AUSTRALIA PTY. LTD.

Melbourne 429 4766 Sydney 534 2144 Newcastle 61 1668 Adelaide 352 3 0 2 2 B r i s b a n e 4 4 1391 P e r t h 361 7088 L a u n c e s t o n 317004 Darwin 81 6427 &

84 3076

OPERATING AND MAINTENANCE INSTRUCTIONS - WELDMATIC 250 (CP25)

- INTRODUCTION

GENERAL

T h i s m a n u a l h a s b e e n p r e p a r e d e s p e c i a l l y f o r u s e i n fami l ia r - ' i z i n g p e r s o n n e l w i t h t h e d e s i g n , i n s t a l l a t i o n , o p e r a t i o n , m a i n t e n a n c e , a n d t r o u b l e s h o o t i n g o f t h i s e q u i p m e n t , A l l i n f o r m a t i o n p r e s e n t e d h e r e i n s h o u l d b e g i v e n c a r e f u l c o n s i d - e r a t i o n t o a s s u r e opt imum performance of this equipment .

"

RECEIVING/HANDLING.

P r i o r t o i n s t a l l i n g t h i s e q u i p m e n t , c l e a n a l l pack ing material f r o m a r o u n d t h e u n i t a n d c a r e f u l l y i n s p e c t f o r a n y damage t h a t may have occu r red du r ing sh ipmen t . Any claims f o r l o s e s o r damage t h a t may h a v e o c c u r r e d i n t r a n s i t m u s t b e f i l e d by t h e p u r c h a s e r w i t h W e l d i n g I n d u s t r i e s o f A u s t r a l i a P t y . L t d . o r a u t h o r i s e d a g e n t i m m e d i a t e l y ( r e f e r t o EQUIPMENT WARRANTY c a r d e n c l o s e d w i t h O p e r a t i n g I n s t r u c t i o n M a n u a l ) .

When r e q u e s t i n g i n f o r m a t i o n c o n c e r n i n g t h i s e q u i p m e n t , i t i s e s s e n t i a l t o s u p p l y c o r r e c t Plodel i d e n t i f i c a t i o n a n d m a c h i n e se r ia l number.

SAFETY.

Befo re t he equ ipmen t i s p u t i n t o o p e r a t i o n , t h e SAFETY PRACTICES s e c t i o n a t the back of t h i s m a n u a l MUST BE READ COMPLETELY. T h i s w i l l h e l p a v o i d p o s s i b l e i n j u r y d u e t o m i s u s e o r i m p r o p e r w e l d i n g a p p l i c a t i o n s .

CONTENTS PAGE NO.

G e n e r a l D e s c r i p t i o n 1

S e t t i n g up f o r O p e r a t i o n 2 - 3

W e l d i n g O p e r a t i o n I n s t r u c t i o n s 4

M a i n t e n a n c e I n s t r u c t i o n s 5

Welding Data - Table "C" 6

- Par ts L i s t CP.25-04 I s s u e 1 7

- Assembly Drawing C P . 2 5 - 0 4 I s s u e 1 8

C i r c u i t Diagrams - CP.25-C5 9

Mobile K i t Assembly - AM117

S a f e t y Practices

Guarantee Card

- 1 -

STANDAXD UNIT

The c o n s t r u c t i o n of t h e s t a n d a r d p a c k a g e p l a n t has been des igned f o r i n s t a l l a t i o n a n d o p e r a t i n g i n a wide v a r i e t y o f a p p l i c a t i o n s , such as h i g h p r o d u c t i o n f a c t o r i e s a n d g e n e r a l f a b r i c a t i o n s h o p s .

"WELDMATIC" P l a n t s c o n s i s t o f three basic u n i t s : -

1. C o n s t a n t P o t e n t i a l Rectifier Power Source . 2 . Semi-Automatic Wire Feeder. 3. Welding Gun and Cable Assembly.

S e p a r a t e o p e r a t i n g a n d m a i n t e n a n c e i n s t r u c t i o n s are p rov ided f o r t h e wire feeder a n d gun cables.

1. POWER SOURCE - FEATURES

The s t a n d a r d C . P . r ec t i f i e r power source i s h o u s e d i n a d r i p - p r o o f e n c l o s u r e . L i f t i n g l u g s are p r o v i d e d for c r a n e t r a n s - p o r t a t i o n . F o r u n i t s w i t h wheel mount ing four wheels are p rov ided ; t h e t w o f r o n t wheels are steerable p e r m i t t i n g e a s y movement i n res t r ic ted f l o o r s p a c e . A push bar i s p rov ided on t h e f r o n t of t h e machine and a gas c y l i n d e r carrier w i t h a s u p p o r t bracket and cha in a t t h e rear . A l10 v o l t p l u g s o c k e t i s l o c a t e d o n t h e rear p a n e l f o r c o n n e c t i o n of g a s p r e h e a t e r when we ld ing w i t h C 0 2 gas s h i e l d . L o c a t e d on the f r o n t p a n e l are a ON/OFF switch, coarse v o l t a g e s e l e c t i o n s w i t c h , f i n e v o l t a g e s e l e c t i o n s w i t c h , c o n t r o l f u s e s , wire f e e d e r p l u g s o c k e t and r e c t i f i e r power o u t l e t s o c k e t s .

2 . CONSTRUCTION

The power source i s a C o n s t a n t P o t e n t i a l S i l i c o n D i o d e Rect i f ie r D.C . Welder , wi th a three phase t r ans fo rmer and a three phase rec t i f ie r b r i d g e . C o n n e c t e d i n t h e o u t p u t c i r c u i t i s an i nduc - t a n c e u n i t p r o v i d i n g t h e " i n d u c t a n c e " o r d e g r e e of s l o p e n e c e s - s a r y f o r v a r i o u s w e l d i n g c u r r e n t s . C o o l i n g o f t h e s i l i c o n d i o d e s , t r a n s f o r m e r w i n d i n g s a n d i n d u c t a n c e u n i t i s by a s i n g l e p h a s e a x i a l f a n . The power s o u r c e i s p r o t e c t e d a g a i n s t f a n f a i l u r e a n d o v e r h e a t i n g by thermosta t s mounted on d iode hea t s i n k s .

3 , WELDING PROCESS

Gas metal a rc w e l d i n g w i t h i n t h e c a p a c i t y of t h e power source can be c a r r i e d o u t w i t h t h e f o l l o w i n g e q u i p m e n t : -

a) Semi-automatic wire feeder model W14. b ) Semi-automatic wire f e e d e r w i t h s p o t timer W14-20. c) "Hobar t " spoo l gun w e l d i n g u n i t m o d e l SP9 w i t h CV2 c o n t r o l l e r . d ) "Mini-mig" push and pul l gun and control .

4 . WELDING CAPACITY

Power Source Capaci ty i s as f o l l o w s : - 250 Amps, 32 v o l t s , 100% d u t y c y c l e .

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5 . SUPPLY AND WELDING CABLES.

Power S o u r c e s a r e s u i t a b l e f o r c o n n e c t i o n t o a 415 v o l t 50 H e r t z 3 phase supp ly .

The recommended f u s e s i z e , p r i m a r y c a b l e s i z e and weld ing cable s i z e a re as fo l lows : -

Fuse - 1 5 amp. Pr imary Cable - 4 core 30/0.25 T .R .S . Welding Cable - 1 1 2 1 / 0 . 2 0 T . R . S .

SHIELDING GASES.

Welding Grade C 0 2 f o r a l l m i l d a n d a l l o y s tee l w e l d i n g i n t h i c k n e s s e s r a n g i n g f r o m lmm upwards.

Argon/C02 o r Argon/Oxygen m i x t u r e s f o r a l l a p p l i c a t i o n s on low c u r r e n t s r e q u i r i n g minimum o f s p a t t e r on s h e e t s tee l and for s t a i n l e s s s teel weld ing .

Argon/Oxygen and Argon/C02 m i x t u r e s f o r p r i m e q u a l i t y w e l d i n g of s t a i n l e s s s teel .

Argon (pu re ) fo r all aluminium welding.

SETTING UP UNIT FOR OPERATION.

- Genera l Assembly of Packaged P l an t (Refer Drawing AM117)

Welding machine i s sh ipped as a s k i d mounted u n i t . I f t h e mach ine has been supp l i ed w i t h wheels and bo t t l e carr ier t h e y s h o u l d be f i t t e d on the machine as shown on Drawing AM217. I f a "Mini-Boom" wire feeder mounting i s s u p p l i e d , l o c a t e t h e v e r t i c a l boom p o s t i n t h e s p e c i a l swivel mount a t t h e rear of the mach ine . Loca te t he "Wire Feeder" on the swivel mount, e n s u r i n g t h a t t h e f i b r e t h r u s t washer i s on t h e p i v o t p i n . Check t h a t t h e "Wire Feeder" i s free t o s w i v e l i n a11 d i r e c t i o n s . I f n e c e s s a r y a p p l y a small amount of g raphi te grease t o s h a f t .

b ) Connect ion to Mains Supply .

Note: This work shou ld on ly be done by a q u a l i t f i e d e lec t r ic ian . The power source i s d e s i g n e d f o r c o n n e c t i o n t o 415 v o l t , 50 h e r t z , 3 p h a s e s u p p l y a n d t h e s u p p l y v o l t a g e s h o u l d be a s c e r t a i n e d b e f o r e connec t ing t he mach ine . Access t o s u p p l y c o n n e c t i o n t e r m i n a l s i n machine may b e g a i n e d b y d o o r i n r i g h t h a n d s ide p a n e l . Use a f l e x i b l e 4 core pr imary cable fo r por tab le machines and c lamp cable t o e n s u r e t h a t there i s no s t r a i n on cable c o n n e c t i o n s . The ea r th ( o r g r o u n d ) c o n n e c t i o n ( g r e e n / y e l l o w ) m u s t b e s e c u r e l y f a s t e n e d t o t h e ' e a r t h ' t e r m i n a l on the mach ine ad jacen t t o t h e s u p p l y c o n n e c t i o n t e r m i n a l s .

- CAUTION B e f o r e i n s e r t i n g p r i m a r y c a b l e p l u g i n m a i n s s u p p l y s o c k e t , e n s u r e t h a t switch on bo th p lug socke t and we ld ing mach ine i s i n 'OFF' p o s i t i o n .

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c ) Connection of Cables/Hoses, e t c , With u n i t switched 'OFF' connect control cable (4 pin plug) from power source to wire feeder. Connect gas hose from. wire feeder t o gas regulator/flowmeter, ensuring a l l connections are tightened f i rmly . If C 0 2 Gas Shield i s being used, plug heater into 110 volt socket at rear of u n i t . Next i n se r t gun cable into socket of wire feeder output guide and re ta in i n place w i t h s e t 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.

c l ) WELDING CABLES.

A l l G.M.A. welding i s done w i t h electrode wire connected t o "positive" pole commonly known as D.C. reverse polarity (D.C.R.P . ) therefore, connect the short jum.per lead from. l '+' '

socket on machine to terminal lug on gun cable. The work Lead ("negative") should be plugged i n t o the ' ' - I t socket on the machine. The plugs of the welding cables must be f u l l y inserted i n the sockets, t o prevent accidental disconnection. T o avoid e r ror , welding should not be attempted u n t i l a l l connections have been secured. The wire feeder may be ins ta l led remote from. the power source, i n which case, extension lead sets corn- prising power cable, gas hose and control cable(four core) are required i n accordance w i t h the desired 1ength.Standard length available from. stock i s 9 metres.

3 ) WIRE FEEDER AND GUN CABLE.

F i t a spool sf wire to the wire feeder (see notes i n "Wire Feeder Instruction Manual") Tighten the "brake" screw u n t i l a sl ight braking effect i s f e l t when turning the wire spool by hand to prevent "over-run" when wire feed stops. The wire dr ive ro l l s and inlet wire guide should be selected i n accord- ance w i t h the diameter and type of wire being used. Refer t o current wire feeder manual for correct selection of wire feed r o l l s and input guides.

0.8mm = 0.030" 0.9mm. = 0.035" 1.2m = 0.045"

The gun cable and gun are normally delivered w i t h t h e contact t i p and l iner spring for wire size nominated, b u t check tha t both are correct size for wire being used.

i, i- - 5 L 3

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W E L D I N G OPERATION INSTRUCTIONS -

8 . SINGLE FUNCTION CHECK

Un i t i s now r e a d y f o r o p e r a t i o n , b u t p r i o r t o commencing weld- i n g , t h e f o l l o w i n g " f u n c t i o n s c h e c k " i s recommended, switch on power source and check a i r f low. See t h a t a l l w e l d i n g l e a d p l u g s are i n s e r t e d i n t h e c o r r e c t p o l a r i t y s o c k e t s - e l e c t r o d e " p o s i t i v e " , work " n e g a t i v e " . Check a l l w e l d i n g c o n n e c t i o n s a n d p l u g s f o r t i g h t n e s s p a r t i c u l a r l y "work" clamp.

Nex t ensu re t h a t a l l c o n t r o l cables and gas hoses are s e c u r e l y connected and t h a t Gas Heater ( f o r C 0 2 o n l y ) i s p l u g g e d i n t o s o c k e t a t r ea r of power source. Switch on wire f e e d e r , i n d i c - a t o r l i g h t s h o u l d now show "Power On". Open Gas c y l i n d e r f u l l y a n d c h e c k c o n t e n t s g a u g e f o r a d e q u a t e g a s s u p p l y .

Press "Gas Purge" swi tch and se t gas f l o w i n a c c o r d a n c e w i t h w e l d i n g r e q u i r e m e n t s , a t t h e same t i m e c h e c k t h a t g a s f l o w i s adequa te from g u n n o z z l e . S e t "wire s p e e d " c o n t r o l t o d e s i r e d wire speed . Press "wire inch" swi t ch and check wire feed f o r c o r r e c t p r e s s u r e o n dr ive r o l l s . P r e s s u r e s h o u l d b e s u f f i c i e n t t o p r e v e n t a n y ' ' s l i p " when f eed ing t h rough gun and cab le .

Next , close gun swi t ch momenta r i ly fo r wire feed , gas f l ow and welding power check. S e t t h e v o l t a g e s e l e c t o r s w i t c h e s i n a c c o r d a n c e w i t h r e q u i r e d v o l t a g e (see we ld ing t ab le ) , u n i t i s now r e a d y f o r w e l d i n g . .

9 . SETTING O F WELDING CURRENT AND VOLTAGE

W e l d i n g c u r r e n t i s d e t e r m i n e d a u t o m a t i c a l l y b y t h e 'wire s p e e d ' . The e l e c t r o d e wire i s f e d a t t h e p r e - s e l e c t e d s p e e d b y d r i v e r o l l s t h r o u g h t h e gun c a b l e t o t h e arc a t a c o n s t a n t s p e e d , unchanged except when reset by t h e 'wire s p e e d ' c o n t r o l . The h i g h e r t h e wire s p e e d , t h e h i g h e r t h e w e l d i n g c u r r e n t .

The o u t p u t v o l t a g e o f t h e power source when t h e gun s w i t c h i s c l o s e d , i s d i v i d e d i n t o a number of s t e p s by c o a r s e selector a n d f i n e s e l e c t o r s w i t c h e s . The ' c o a r s e ' s e l e c t o r s w i t c h w o r k s i n c o n j u n c t i o n w i t h a " f i n e " selector s w i t c h g i v i n g 3 0 v o l t a g e s t e p s . The fo l lowing s equence o f weld s e t t i n g i s recommended:-

a ) C o n s u l t t y p i c a l weld s e t t i n g c h a r t . b ) Select w e l d i n g c u r r e n t m o s t s u i t e d t o t h e a p p l i c a t i o n b y f o l l o w i n g t h e s e t t i n g s o f wire speed and vo l t age shown on t h e s e t t i n g c h a r t . To " t u n e " e a c h weld s e t t i n g , a d j u s t wire speed o n l y . c) I f v o l t a g e i s t o o low f o r t h e a p p l i c a t i o n , wire " s t u b b i n g " w i l l o c c u r , p a r t i c u l a r l y a t s t a r t of weld and weld c o n t o u r w i l l be v e r y c o n v e x . I f t h e v o l t a g e i s t o o h i g h , metal t r a n s f e r w i l l be e r r a t i c w i t h e x c e s s s p a t t e r , d) W i t h w e l d i n g c u r r e n t a n d v o l t a g e m a t c h e d t h e r e s u l t w i l l be an op t imum tuned weld ing condi t ion wi th a s m o o t h s p a t t e r - f r e e arc.

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10. SAFETY DEVICES

I n the event of the power source becoming overheated the ther- mostats on the diode heat s i n k s w i l l operate preventing further welding. The thermostats will automatically reset and w i t h the cooling fan operating t h i s w i l l 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 a l l c i rcu i t s a re as fo l lows and are indicated on the front panel:-

Fuse E l - 3 amps (Delayed action) Fuse E2 - 3 amps ( Fuse E 3 - 5 amps ( Fuse E4 - 5 amps (

I 1

I1

I 1

I' 1 I ' ) " 1

11. MAINTENANCE

a ) Power Source Apart from the fan the rectifier has no rotary components. T o achieve complete dissipation of heat from the active components, t he r ec t i f i e r should be thoroughly blown off w i t h d ry compressed a i r a f t e r 6 months' operation. Cleaning should be carried out a t sho r t e r i n t e rva l s i f d u s t accumulation i s considerable.

Prior to cleaning, remove the u n i t cover by detachment of lugs and the f ixing screws. Thus all the components of the power source w i l l be accessible.

b ) The wire feed motor/gearbox i s pre-packed w i t h grease and needs no other lubrication. Change the grease after approximately 14,000 service hours. (see Wire Feeder Instruction Manual).

The dr ive ro l le rs and the inner wire guides should be kept clean. If necessary, blow off the inside of the wire feeder w i t h compressed a i r .

c ) Gun and Cable Remove any spat ter which might adhere to t he nozzle bore so that the shielding gas outflow i s not impeded. The condition of the contact tubes should be regularly checked. Damaged and/ o r b u r n t tubes are an impediment to t rouble-free welding operation and should be replaced immediately.

Trouble-free operation depends t o a large extent on the good condition and cleanliness of the inner wire l iner (See Instruc- t ions on Gun Cables).

1 2 . WELDING OPERATION

Never observe the arc w i t h unprotected eyes. It i s of impsrt- ance that the welder wear protective clothing providing suffic- ient safety.

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13. STOPPAGES AND THEIR ELIMINATION

The machine shou ld be checked only by a fu l ly sk i l led e lec t r ic ian . If the u n i t stops working, f i r s t determine whether stoppages are i n i t i a t e d by the mains (for instance, b u r n t fuse) or by the supply cable (loose connection, cable break) or by the u n i t proper.

If the three terminals L1, L2 and L3 on the primary terminal board are correct ly connected t o the mains (voltmeter reading) t h e cause of the stoppage must be sought i n the u n i t i t s e l f .

The wiring diagram on the next pages w i l l f ac i l i t a te the loca t ion of the defect.

WELDING DATA - TYPICAL VALUES

Shielding Gas i s welding Grade C02 used w i t h a Gas Preheater. Contact Tip 1.5mrd inside of Gas Nozzle, Wire "Stick Outt1 6 - 9m.mup to 200 amps. 9 - 12mmover 200 amps. These Tables are a guide only for i n i t i a l machine se t t i ng and finer adjustments may be necessary t o achieve optimum welding charac te r i s t ics for the application. Recommended machine se t t ing method i s t o s e t Voltage Switches, Inductance and Gas Flow as per Table then adjust wire speed to ob ta in recommended current.

0 , $m- Wire Speed Volts Amps . l.g(metres/min) 18.0 50 3.0 'I 17.0 75 3.7 18.0 85 4.1 I t 19.0 100 5.0 I ' 19.5 1 2 0 6,8 I t 21.5 150 9.2 23.0 1 7 5 '2.1 I t 25.0 200 -6.8 ' I II 32.0 250

I I

I1

I1

l 1

I1

I 1 I I

I1

3, c 2mm MILD STEEL WIRE

Wire Speed Volts Amps.

2.5(rnetres/min) 18.0 100 2.9 18.5 130 3.3 19.0 140 4.0 20.0 160 5.3 23.0 200 6.4 23.0 230 8.2 28.0 250 10.8 I 1 I t 32.0 280 13.4 32.0 300

I 1 I I

I I 11

I I I 1

I1 11

I I I1

It I t

I 1 I1

NOTE: Wire speed i s shown i n metres/minute and are not dial cal ibrat ion set t ings.

- DRAWING NO. CP25-04 ISSUE N O . l . 7:

- ITEM NO.

l 2

3

4

5

6

7

8

9

10 11 1 2

1 3

1 4 1 5

1 6

1 7

18 19

2 0

2 1

2 2

2 3

2 4

2 5

2 6

2 7

2 8

- PART NO.

CP25-45

CP25-34

C P 1 5 - l 4

CP29-0/6

CP29-0/6

CP25-50

CP15-0/7

CP2-0/13

CP3-0/30

CP3-0/35

CP3-0/47

dl- 2 2

Xl- 2 3

=1P29-0/20

2P25-0/18 '

ZP25-04/16

3 ? 1 5 - 0 / 1 4

3 ' 2 5 - 4 9

3P25-46

c1P35-13

3 P 3 5 - 1 4 / 1

31?35-14/2

c1P25-48

U N 4 4

: IC14-1 /14

ZP35-18

U41 6

L0029F

DESCRIPTION

BASE FKAME ASSEMBLY

TRANSFORT.IER ASSEL-BLY

INDUCTANCE ASSEE43LY

FAN BLADE

FAN MOTOR

RECTIFIER ASSEMBLY

GAS HEATER PLUG

WELDING CONTACTOR

AI,V.IF:TER SHUNT 0-400A.

AllPlETER 0-400A

VOLTMETER 0-6011.

INDICATOR LIGHT

FUSE HOLDER

OFF/ON SWITCH

FINE SELECTOR SWITCH

COARSE SELECTOR SWITCH

CONTROL PLUG

FRONT PANEL

BACK PANEL

TOP COVER

LEFT HAND SIDE COVER

RIGHT HAND SIDE COVER

CONTACTOR & SWITCH BAFFLE PLATE

TYPE NO./SERIAL NO. PLATE

TERMINAL STRIP

T I E BAR

OUTPUT TERMINALS

EYE NUT

8

n I \

0- B- I I

I l -

0 m cu

@ l l I

"Q

I

r a

n

I-" 1 : I I

l I I I

l

I I l '

- L 1 I 4

I N . m

J

T I

m

m

l 0 C

WELDMATIC 250

MODEL NO. C P 2 5

”””””

CAT. 7523/25

5/79

THE INFORMATION CONTAINED I N THE FOLDER I S SET OUT TO ENABLE YOU TO PROPERLY MAINTAIN YOUR NEW EQUIPMENT AND ENSURE THAT YOU OBTAIN MAXIMUM O P E R A T I N G E F F I C I E N C Y .

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84 3076

OPERATING AND MAINTENANCE INSTRUCTIONS

WELDMATIC 250 (CP25)

INTRODUCTION

GENERAL This manual has been prepared e s p e c i a l l y fo r u s e i n famil iar- i z i n g p e r s o n n e l w i t h t h e d e s i g n , i n s t a l l a t i o n , o p e r a t i o n , ma in tenance , and t roub le shoo t ing of t h i s e q u i p m e n t . A l l i n f o r m a t i o n p r e s e n t e d h e r e i n s h o u l d be g i v e n c a r e f u l c o n s i d - e r a t i o n t o a s s u r e optimum performance of t h i s e q u i p m e n t .

RECEIVING/HANDLIN~.

P r ior t o i n s t a l l i n g t h i s e q u i p m e n t , c l e a n a l l pack ing material from around t h e u n i t and c a r e f u l l y i n s p e c t for any damage t h a t may have occu r red du r ing sh ipmen t . Any claims fo r loses or damage t h a t may h a v e o c c u r e d i n t r a n s i t m.ust be f i l e d by t h e p u r c h a s e r w i t h W e l d i n g I n d u s t r i e s of A u s t r a l i a P t y . L t d . or a u t h o r i s e d a g e n t immediately ( re fer t o EQUIPMENT WARRANTY card e n c l o s e d w i t h O p e r a t i n g I n s t r u c t i o n M a n u a l ) .

When r e q u e s t i n g i n f o r m a t i o n c o n c e r n i n g t h i s equipment , it i s e s s e n t i a l t o supp ly correct Model i d e n t i f i c a t i o n a n d m a c h i n e ser ia l number.

SAFETY e

Before the equ ipmen t i s p u t i n t o o p e r a t i o n , t h e SAFETY PRACTICES s e c t i o n a t t h e back of t h i s manual MUST BE READ COMPLETELY. T h i s w i l l help avo id possible i n j u r y d u e t o misuse or improper w e l d i n g a p p l i c a t i o n s .

CONTENT S PAGE NO.

G e n e r a l D e s c r i p t i o n 1

S e t t i n g u p for Opera t ion 2 - 3

W e l d i n g O p e r a t i o n I n s t r u c t i o n s 4

Maintenance Instructions 5

Welding Data - T a b l e "C" 6

- P a r t s L i s t CP. 25-01 I s s u e 2 7

- Assembly Drawing CP. 25-01 I s s u e 2 8

C i r c u i t D i a g r a m s - CP.25-C 3 9

Mobile K i t Assembly - AM51

S a f e t y Practices

Guarantee Card

1 2 3 4 5 6 7 8 9 10 11 1 2 1 3 1 4 15 1 6 1 7 18 1 9 2 0 2 1 2 2 23 2 4 25 2 6 27 28 2 9 30 3 1 32 33 34 35 36 37

PART NO.

CP35-l1 CP25-11 CP25-16 CP24-0 /4 CP24-0/5 CP3-9 CP25-0/7 CP2-0/9 CP3-62 CP2-0/13 CP3-0/30 CP3-0/35 CP3-0/44 w1- 2 2 1 0 7 1 - 2 3 CP25-0/18 C225-0/19 CP2-0/31 CP25-19 CP35-12 CP35-13 CP35-14/1 CP35-14/2 CP35-15 W I N 4 4 CP35-17 A M 1 6 CP25-26 CP35-18 CP35-19 10029F T C 2 6 2 TC262N 1030010 MC40-20/3 Cl?35-0/37 CP35-0/38

7

DRAWING NO. CP25-01 ISSUE NO. 2

DESCRIPTION

Frame Assembly Transformer Assembly Inductance Assembly Fan Blade Fan Motor Rectifier Assembly Cont ro l T rans fo rmer Gas Heater P l u g Rectifier P r o t e c t i o n A s s e m b l y Welding Contactor Ammeter Shun t Ammeter 0 - 4 0 0 Amps Voltmeter 0 - 60 Volt I n d i c a t o r L i g h t Fuse Holders F i n e S e l e c t o r S w i t c h Coarse S e l e c t o r S w i t c h C o n t r o l P l u g F r o n t P a n e l Back P a n e l Top Cover L e f t Hand S i d e Cover R i g h t Hand S i d e Cover C o n t a c t o r a n d S w i t c h B a f f l e Plate Type No. S e r i a l No. P l a t e Terminal Assembly Output Terminals T rans fo rmer Suppor t T i e Bar Fan Mounting Bracket Eye Nut Gas O u t l e t F i t t i n g Nut f or Above 3/4"W x 3" Hex. HD. S e t S c r e w . B a k e l i t e I n s u l a t o r s Loom Assembly Zas Hose

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5 . - SUPPLY AND WELDING CABLES.

Power Sources are s u i t a b l e f o r c o n n e c t i o n t o a 415 v o l t 5 0 Hertz 3 phase supp ly .

The recommended f u s e s i z e , p r i m a r y cable s i z e a n d w e l d i n g c a b l e s i z e a re as follows:-

a ) Fuse - 15 amp. b ) Primary Cable - 4 core 30/0.25 T.R.S. c ) Welding Cable - 1121/0.20 T.R.S.

6 . SHIELDING GASES.

a ) Welding Grade C 0 2 for a l l m i l d a n d a l l o y s t e e l w e l d i n g i n

b ) Argon/CO2 or Argon/Oxygen m i x t u r e s for a b 1 a p p l i c a t i o n s on t h i c k n e s s e s r a n g i n g f r o m lmm upwards.

low c u r r e n t s r e q u i r i n g minimum of spatter on s h e e t s teel and for s t a i n l e s s s teel welding.

of s t a i n l e s s s t ee l , c ) Argon/Oxygen and Argon/C02 m i x t u r e s for prime q u a l i t y w e l d i n g

d ) Argon ( p u r e ) f o r a l l aluminium welding.

7 . SmTING UP UNIT FOR OPERATION.

a ) General Assembly of Packaqed P l an t (Refer Drawing AM511 The Rectifier Welder i s s h i p p e d w i t h t h e s k i d s or whee l s unbo l t ed . B o l t on t h e wheel assemblies w i t h t h e steerable ( s w i v e l ) w h e e l s n e a r e s t t h e f r o n t p a n e l a n d p u s h bar. I f a "Mini-Boom." wire f eede r moun t ing i s s u p p l i e d , locate t h e v e r t i c a l boom p o s t i n t h e special swivel mount a t t h e rear o f t he mach ine . Locate t h e Wire Feeder o n t h e swivel mount , ensur ing t h a t t h e f ibre t h r u s t washer i s on t h e p i v o t p i n . Check t h a t t h e "Wire Feede r" i s free t o s w i v e l i n all d i r e c t i o n s . I f n e c e s s a r y a p p l y a small amount of g r a p h i t e grease t o s h a f t .

-

b ) Connect ion t o Mains Supply.

Note: T h i s work should only be done by a q u a l i f i e d e l e c t r i c i a n . The power s o u r c e i s des igned for c o n n e c t i o n t o 415 v o l t , 50 h e r t z , 3 p h a s e s u p p l y a n d t h e s u p p l y v o l t a g e s h o u l d be ascert- ained before c o n n e c t i n g t h e machine. Access t o supply connec- t i o n t e r m i n a l s i n m a c h i n e may be ga ined by door i n r i g h t hand side p a n e l . U s e a f l e x i b l e 4 c o r e p r i m a r y c a b l e fo r portable machines and clamp cable to e n s u r e t h a t t h e r e i s no s t r a i n on cable connec t ions . The ear th ( o r g r o u d ) c o n n e c t i o n ( g r e e n / y e l l o w ) m u s t be s e c u r e l y f a s t e n e d t o t h e ' e a r t h ' t e r m i n a l o n t h e m a c h i n e a d j a c e n t t o t h e , s u p p l y c o n n e c t i o n t e r m i n a l s .

" CAUTION Before i n s e r t i n g p r i m . a r y cable p l u g i n m a i n s s u p p l y socket, e n s u r e t h a t s w i t c h on bo th plug socket and we ld ing machine i s i n 'OFF' p o s i t i o n .

- 1. -

STANDARD U N I T

The c o n s t r u c t i o n of t h e s t a n d a r d p a c k a g e p l a n t has been des igned f o r i n s t a l l a t i o n and o p e r a t i n g i n a wide v a r i e t y of a p p l i c a t i o n s , such as h i g h p r o d u c t i o n f a c t o r i e s a n d g e n e r a l f a b r i c a t i o n s h o p s .

"V!ELDE.WTI:C" P l a n t s c o n s i s t of three bas i c u n i t s : -

l. C o n s t a n t P o t e n t i a l R e c t i f i e r Power Source . 2 . Semi-Automatic Wire Feede r . 3 . Welding Gun and Cable Assembly.

Separate o p e r a t i n g a n d m a i n t e n a n c e i n s t r u c t i o n s a re p r o v i d e d for t h e wire feeder and gun cab les .

l. POWER SOURCE - FEATURES

The s t a n d a r d C . P . r ec t i f i e r power source i s h o u s e d i n a d r i p - p r o o f e n c l o s u r e , L i f t i n g l u g s are p rov ided for c r a n e t r a n s - p o r t a t i o n . For u n i t s w i t h w h e e l m o u n t i n g f o u r w h e e l s are p r o v i d e d ; t h e t w o f r o n t w h e e l s are steerable p e r m i t t i n g e a s y movement i n res t r ic ted f l o o r s p a c e . A push ba r i s p r o v i d e d on the f r o n t of t h e machine and a g a s c y l i n d e r car r ie r w i t h a s u p p o r t bracket and cha in a t t h e r ea r . A 110 v o l t p l u g socket i s l o c a t e d o n t h e rear p a n e l f o r c o n n e c t i o n o f g a s p r e h e a t e r when w e l d i n g w i t h C02 g a s s h i e l d . L o c a t e d on t h e f r o n t p a n e l a re a ON/OFF s w i t c h , c o a r s e v o l t a g e s e l e c t i o n s w i t c h , f i n e v o l t a g e s e l e c t i o n swi t ch , c o n t r o l f u s e s , wire f e e d e r p l u g socket and r ec t i f i e r power o u t l e t s o c k e t s .

2 . CONSTRUCTION

The power source i s a C o n s t a n t P o t e n t i a l S i l i c o n D i o d e Rect i f ier D . C . Welder, w i t h a three phase t r ans fo rmer and a three phase r ec t i f i e r b r i d g e . C o n n e c t e d i n t h e o u t p u t c i r c u i t i s an i nduc - tance u n i t p r o v i d i n g t h e " i n d u c t a n c e " o r d e g r e e of s l o p e n e c e s - s a r y f o r v a r i o u s w e l d i n g c u r r e n t s . C o o l i n g o f t h e s i l i c o n d i o d e s , t r a n s f o r m e r w i n d i n g s a n d i n d u c t a n c e u n i t i s by a s i n g l e p h a s e a x i a l f a n . The power s o u r c e i s p r o t e c t e d a g a i n s t f a n f a i l u r e and ove rhea t ing by thermostats moun ted on d iode hea t s inxs .

3. WELDING PROCESS

Gas metal a rc w e l d i n g w i t h i n t h e c a p a c i t y o f t h e power source can be c a r r i e d o u t w i t h t h e fo l lowing equ ipmen t : -

a ) Semi-automatic wire feeder model W14. b) Semi-automatic wire feeder w i t h s p o t timer W14-20. c) "Hobar t" spool gun we ld ing un i t mode l SP9 w i t h CV2 c o n t r o l l e r . d ) "Plini-mig" push and p u l l gun and con t ro l .

4. WELDING CAPACITY

Power: Source Capac i ty i s as fo l lows : - 250 Amps, 32 v o l t s , 1 0 0 % d u t y c y c l e .

5. SUPPLY AND WELDING CABLES.

Power Sources are s u i t a b l e for c o n n e c t i o n t o a 415 v o l t 50 H e r t z 3 phase supp ly .

The recommended f u s e s i z e , p r i m a r y c a b l e s i z e and we ld ing cab le s i z e are as follows:-

a) Fuse - 15 amp. b) Pr imary Cable - 4 core 30/0.25 T.R. S. c) Welding Cable - 1 1 2 1 / 0 . 2 0 T . R . S .

6 . S H I E L D I N G GASES.

a ) a- Welding Grade C 0 2 f o r a l l m i l d a n d a l l o y s tee l w e l d i n g i n t h i c k n e s s e s r a n g i n g f r o m lm upwards.

b ) Argon/C02 o r Argon/Oxygen m i x t u r e s f o r a l l a p p l i c a t i o n s on low c u r r e n t s r e q u i r i n g minimum of s p a t t e r o n s h e e t s teel a n d for s t a i n l e s s s t ee l we ld ing .

c) Argon/Oxygen and Argon/C02 m i x t u r e s f o r p r i m e q u a l i t y w e l d i n g of s t a i n l e s s s teel .

d ) Argon (pu re ) fo r a l l aluminium welding.

7 . SETTING UP UNIT FOR OPERATION.

a) - General Assembly of Packaged Plant (Refer Drawing AM117)

The Welding machine i s sh ipped as a skid mounted u n i t . I f t h e m a c h i n e h a s b e e n s u p p l i e d w i t h w h e e l s a n d b o t t l e c a r r i e r t h e y s h o u l d be f i t t e d on the machine as shown on Drawing AM117. If a "Mini-Boom" wire f eede r moun t ing i s s u p p l i e d , locate t h e v e r t i c a l boom p o s t i n t h e s p e c i a l swivel mount a t t h e rear of the mach ine . Loca te t he "Wire F e e d e r " o n t h e swivel mount, e n s u r i n g t h a t t h e f i b r e t h r u s t w a s h e r i s on t h e p i v o t p i n . Check t h a t t h e "Wire Feeder" i s f ree t o swivel i n a11 d i r e c t i o n s . I f n e c e s s a r y a p p l y a small amoun t o f g raph i t e g rease t o s h a f t .

b) Connect ion t o Mains Supply.

Note : This work should on ly be done by a q u a l i t f i e d e l e c t r i c i a n . The power source i s d e s i g n e d f o r c o n n e c t i o n t o 415 v o l t , 50 h e r t z , 3 p h a s e s u p p l y a n d t h e s u p p l y v o l t a g e s h o u l d b e a s c e r t a i n e d b e f o r e connec t ing t he mach ine . Access t o s u p p l y c o n n e c t i o n t e r m i n a l s i n machine .may be ga ined by d o o r i n r i g h t h a n d s i d e p a n e l . Use a f l e x i b l e 4 c o r e p r i m a r y c a b l e for por tab le machines and c lamp cable t o e n s u r e t h a t t h e r e i s no s t r a i n on c a b l e c o n n e c t i o n s . The e a r t h ( o r g r o u n d ) c o n n e c t i o n ( g r e e n / y e l l o w ) m u s t b e s e c u r e l y f a s t e n e d t o t h e ' e a r t h ' t e r m i n a l on t h e m a c h i n e a d j a c e n t t o t h e s u p p l y c o n n e c t i o n t e r m i n a l s .

- CAUTION B e f o r e i n s e r t i n g p r i m a r y c a b l e p l u g i n m a i n s s u p p l y s o c k e t , e n s u r e t h a t s w i t c h on bo th p lug socket and weld ing machine i s i n 'OFF' p o s i t i o n .

- 4 -

W E L D I N G - O P E R A T I O N I N S T R U C T I O N S

8. S I N G L E FUNCTION CHECK

Un i t i s now r e a d y f o r o p e r a t i o n , b u t p r i o r t o cbmmencing weld- i n g , t h e f o l l o w i n g " f u n c t i o n s c h e c k " i s recommended, switch on power source and check a i r flow. See t h a t a l l we ld ing lead p l u g s are i n s e r t e d i n t h e c o r r e c t p o l a r i t y s o c k e t s - e l e c t r o d e " p o s i t i v e " , work " n e g a t i v e " . Check a l l w e l d i n g c o n n e c t i o n s a n d p l u g s f o r t i g h t n e s s p a r t i c u l a r l y " w o r k " c l a m p .

Nex t ensu re t h a t a11 c o n t r o l cables and gas hoses are s e c u r e l y connec ted and t h a t Gas Heater ( f o r CO2 o n l y ) i s p l u g g e d i n t o s o c k e t a t rear sf power source. Swi t ch on wire f e e d e r , i n d i c - a tor l i g h t s h o u l d now show "Power On". Open Gas c y l i n d e r f u l l y a n d c h e c k c o n t e n t s g a u g e f o r a d e q u a t e g a s s u p p l y .

Press "Gas Purge" switch and s e t gas f l o w i n a c c o r d a n c e w i t h w e l d i n g r e q u i r e m e n t s , a t t h e same t i m e check t h a t gas f low i s adequate f rom gun nozz le . Set "wire s p e e d " c o n t r o l t o desired wire speed . Press "wire i n c h " s w i t c h and check wire feed f o r c o r r e c t p r e s s u r e on d r i v e ro1l.s. P r e s s u r e s h o u l d b e s u f f i c i e n t t o p r e v e n t a n y " s l i p " when feeding through gun and cable.

Next , c lose gun switch m o m e n t a r i l y f o r wire feed, gas flow and welding power check. S e t t h e v o l t a g e s e l e c t o r switches i n a c c o r d a n c e w i t h r e q u i r e d v o l t a g e (see w e l d i n g tab le) , u n i t i s now r e a d y f o r w e l d i n g .

9 . - SETTING OF W E L D I N G CURRENT AND VOLTAGE

W e l d i n g c u r r e n t i s d e t e r m i n e d a u t o m a t i c a l l y b y t h e 'wire s p e e d ' The e l e c t r o d e w i r e i s fed a t t he p r e - s e l e c t e d s p e e d b y d r ive r o l l s t h r o u g h the gun cable t o t h e a rc a t a c o n s t a n t s p e e d , unchanged except when reset by t h e 'wire s p e e d ' c o n t r o l . The h i g h e r t he wire speed , the h i g h e r t he w e l d i n g c u r r e n t .

The o u t p u t v o l t a g e of t h e power source when t h e gun s w i t c h i s c l o s e d , i s d i v i d e d i n t o a n u m b e r o f s t e p s b y c o a r s e s e l e c t o r a n d f i n e selector switches. The 'coarse' s e l e c t o r s w i t c h w o r k s i n c o n j u n c t i o n w i t h a " f i n e " s e l e c t o r switch g i v i n g 30 v o l t a g e steps . The f o l l o w i n g s e q u e n c e o f w e l d s e t t i n g i s recommended:-

a ) C o n s u l t t y p i c a l weld s e t t i n g c h a r t . b ) Select w e l d i n g c u r r e n t m o s t s u i t e d t o t he a p p l i c a t i o n by f o l l o w i n g t h e s e t t i n g s of wire s p e e d a n d v o l t a g e shown on t h e s e t t i n g char t . To " t u n e " e a c h weld s e t t i n g , a d j u s t wire speed o n l y . .c) If v o l t a g e i s t o o low f o r t h e . a p p l i c a t i o n , wire " s t u b b i n g " w i . 1 1 o c c u r , p a r t i c u l a r l y a t s t a r t o f weld and weld c o n t o u r w i l l be very convex. If t h e v o l t a g e i s t o o h i g h , metal t r a n s f e r will be e r r a t i c w i t h e x c e s s s p a t t e r , d) With w e l d i n g c u r r e n t a n d v o l t a g e matched t h e r e s u l t w i l l be an op t imum tuned weld ing condi t ion wi th a s m o o t h s p a t t e r - f r e e arc.

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c ) Connection of Cables/Hoses, e tc . W i t h u n i t switched 'OFF' connect control cable (4- pin plug) from. power source to wire feeder, Connect gas hose from wire feeder to gas regulator/flowmeter, ensuring a l l connections are tightened firmly. If C 0 2 Gas Shield i s being used, plug heater into 110 volt socket a t rear of u n i t . Next i n s e r t gun cable into socket of wire feeder output guide and r e t a in i n place w i t h s e t screw provided, Set screw should n o t be tightened so as t o prevent gun cable from swivelling. Connect "Gas Hose" and "Gun Switch" leads to respective sockets.

a ) WELDING CABLES.

A l l G,M.A. welding i s done w i t h electrode wire connected t o "positive" pole commonly known as D.C. reverse polar i ty (D.C.R.P . ) therefore, connect the short jumper lead from ' I + ' '

socket on machine t o term.ina1 lug on gun cable. The work lead ("negative") should be plugged in to the 'I-'' socket on the machine. The plugs of the welding cables must be f u l l y inserted in the sockets, .to prevent accidental disconnection. To avoid error , welding should not be attempted u n t i l a l l connections have been secured. The wire feeder may be ins ta l led remote from. the power source, i n which case, extension lead sets com- pr is ing power cable, gas hose and control cable(four core) are required i n accordance w i t h the desired 1ength.Standard length available from stock i s 9 metres.

3) WIRE FEEDER AND GUN CABLE.

F i t a spool of wire t o the wire feeder (see notes i n "Wire Feeder Instruction Manual") . Tighten the "brake" screw u n t i l a s l i g h t braking effect i s f e l t when turning the wire spool by hand t o prevent "over-run" when wire feed stops, The wire d r ive ro l l s and inlet wire guide should be selected i n accord- ance w i t h the diameter and type of wire being used. Refer t o 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 w i t h the contact t i p and l iner spr ing for wire s ize nominated, but check t h a t both are correct size for wire being used.

-6-

13. STOPPAGES AND THEIR ELIMINATION

The machine should be checked on ly by a f u l l y s k i l l e d e l e c t r i c i a n . If t h e u n i t s t o p s w o r k i n g , f i r s t determ.ine whethei '3stoppages a re i n i t i a t e d b y t h e mains ( fo r i n s t a n c e , b u r n t f u s e ) or by t h e s u p p l y c a b l e (loose c o n n e c t i o n , cable b r e a k ) or by t h e u n i t proper.

If t h e t h r e e t e r m i n a l s L1, L2 and L3 o n t h e p r i m a r y t e r m i n a l board are c o r r e c t l y c o n n e c t e d t o t h e m.ains ( v o l t m e t e r r e a d i n g ) t h e cause of t h e s t o p p a g e m.ust be s o u g h t i n t h e u n i t i t s e l f .

The w i r ing d i ag ram on t h e n e x t pages w i l l f a c i l i t a t e t h e l o c a t i o n sf t h e d e f e c t .

0.9rbm MILD STEEL WIRE Wire Speed Volts Amps,

I .g (met res /min) 18.0 50 3.0 I t 19.0 75 3 . 7 I t 18.0 85 4.1 I t 19.0 100 5.0 I t I I 19.5 L20

S

I I

I t

II

6.8 I t It 21.5 158 9.2 23.0 175

.2. l. I I 25.0 200

.6.8 I t I t 32.Q 250

I t

It

WELDING DATA - TYPICAL VALUES S h i e l d i n g Gas i s we ld ing Grade C 8 2 u s e d w i t h a Gas P r e h e a t e r . Contact T i p 1.5mm. i n s i d e sf Gas Nozzle. Wire "S t i ck Ou t " 6 - 9mm.up t o 200 amps. 9 - 12mmover 200 amps. These Tables are a g u i d e o n l y for i n i t i a l m a c h i n e s e t t i n g a n d f i n e r - a d j u s t m e n t s may be n e c e s s a r y t o a c h i e v e o p t i m u m w e l d i n g c h a r a c t e r i s t i c s for t h e application, Recommended m a c h i n e s e t t i n g m e t h o d i s t o set Voltage §wi tches , Inductance and Gas Flow as per Table t h e n a d j u s t wire speed t o o b t a i n recommended c u r r e n t .

l

L, 2mm MILD STEEL WIRE Wire Speed Volts Amps.

2.5(metres/min) 18.0 180 2.9 18.5 130 3 . 3 19.0 140 4.0 20.0 160 5.3 I t 23.0 200 6.4 23.0 230 8.2 28.0 250

I t I I

II It

I t I t

I 1

II II

I t I I

10.8 !I I t 32.0 280

13.4 I1 I t 32.0 300

NOTE: Wire speed i s shown in me t re s /minu te and are n o t d i a l c a l i b r a t i o n s e t t i n g s .

- 5 -

10. SAFETY DEVICES

I n the event of the power source becoming overheated the ther- mostats on the diode heat sinks w i l l operate preventing further welding. The thermostats will automatically reset and w i t h the cooling fan operating t h i s w i l l take approximately 10 minutes. A check should be made to ascertain the reason for the over- heating such as fan not operating or a i r flow re s t r i c t ed . Fuses provided for a l l c i rcu i t s a re as fo l lows and are indicated o n the front panel:-

Fuse E l - 3 amps (Delayed action) Fuse E2 - 3 amps ( Fuse E 3 - 5 amps ( Fuse E4 - 5 amps (

I1

I 1

I I

I1

'l 1

11. MAINTENANCE

a) Power Source Apart from the fan the rectifier has no rotary components. TO achieve complete diss ipat ion of heat from the active components, t he r ec t i f i e r should be thoroughly blown off w i t h d r y compressed a i r a f t e r 6 m o n t h s ' operation. Cleaning should be carried out a t shor te r in te rva ls if d u s t accumulation i s considerable.

Prior to cleaning, remove the u n i t cover by detachment of lugs and the fixing screws. Thus a l l t h e components of the power source w i l l be accessible.

b ) The wire feed motor/gearbox i s pre-packed w i t h grease and needs no other lubrication. Change the grease after approximately 14,000 service hours. (see Wire Feeder Instruction Manual).

The dr ive ro l le rs and the inner wire guides should be kept clean. If necessary, blow off the inside of the wire feeder w i t h compressed a i r .

c ) Gun and Cable Rem.ove any spa t te r which might adhere to the nozzle bore so that the shielding gas outflow i s not impeded. The condition of the contact tubes should be regularly checked.. Damaged and/ or burnt tubes are an impediment to t rouble-free welding operation and should be replaced immediately.

Trouble-free operation.depends t o a large extent on the good condition and cleanliness of the inner wire liner (See Instruc- t ions on Gun Cables).

1 2 . WELDING OPERATION

Never observe the arc w i t h unprotected eyes. I t i s of import- ance tha t the welder wear protective clothing providing suffic- ient safety.

L ' a.

D R A W I N G N O . CP25-03 ISSUE NO. 5 .

ITEM NO.

1 2

3 4

5

6

7

8

9

10 l1 1 2

1 3

1 4 1 5

1 6

17 1 8

19 20

2 1

2 2

2 3

2 4

2 5

26

2 7

2 8

2 9

3 0

31

3 2

33

34

35

36

PART NO.

C P 3 5 - 1 1

CP25-34

CP15-14

CP24-0/4

CP24-0/5

CP25-42

CP15-0/7

CP3-62

CP2-0/13

CP3-0/30

CP3-0/35

CP3-0/47

w1-22

W1-23

CP25-0/18

CP25-03/16

CP15-0/14

CP25-19

CP35-12

CP35-13

CP35-E4/1

CP35-14/2

CP35-15

WIN4 4

CP35-17

ZIP41 6

CP25-26

C P 3 5 - l 8

CP35-19

1 0 0 2 9 F

TC262

TC262N

1 0 3 0 0 1 0

MC40-20/3

CP35-0/37

CP35-0/38

P

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 - 4 0 0 AMPS.

VOLTMETER 0 - 6 0 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

CONTACTOR AND SWITCH BAFFLE PLATE

TYPE N O , SERIAL NO. PLATE

TERMINAL ASSEMBLY

OUTPUT TERMINALS

TRANSFORMER SUPPORT

T I E BAR

FAN MOUNTING BRACKET

EYE NUT

GAS OUTLET FITTING

NUT FOR ABOVE

3/4"W x 3" HEX. H D . SET SCREW

BAKELITE INSULATORS

LOOM ASSEMBLY

GAS HOSE

51

I r- r

I I I m - 1 -

I

I

4 +

I

L. I

DRAWING NO. CP25-03 ISSUE NO. 4

7

DESCRIPTION

Frame Assembly Transformer Assembly Inductance, Assembiy Fan Blade Fan Motor R e c t i f i e r Assembly Gas Heater P l u g Rectifier Pro tec t ion Assembly Welding Contac tor Ammeter Shunt Ammeter 0-400 Amps. Voltmeter 0 - 6 0 V o l t I n d i c a t o r L i g h t Fuse Holders F i n e S e l e c t o r S w i t c h Coarse S e l e c t o r S w i t c h C o n t r o l P l u g F r o n t P a n e l Back P a n e l Top Cover L e f t Hand Side Cover R igh t Hand Side Cover Contac tor and Swi tch Baf f l e Plate

Type N o . S e r i a l N o . P la te

Terminal Assembly 3 u t p u t T e r m i n a l s Transformer Suppor t Tie B a r

Fan Mounting Bracket Eye Nut

Sas O u t l e t P i t t i n g g u t f o r Above 3/4"W x 3" Hex. HD. Se t Screw. 3 a k e l i t e I n s u l a t o r s Loom Assembly ;as Hose

- ITEM NO.

1 2

3 4

5 6

7

8 9

10 11 1 2

13 L4 L5 L6

L7 L8 L9

20

21 22

23 24 !5 !6

!7

!8 !9

IO 31

32

53 l 4

15 16

PART NO.

CP35-l1 CP25-34 CP15-14 C P 2 4 - 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- 2 2

dl-23 2P25-0/18 2P25-03/16 2P2-0/31 2P25-19 3P35-12 "35-13

2P35-14/1 2P35-14/2 2P35-15 4 I N 4 4 2P35-17 W16 5P25-26 3P35-18 2P35-l9 L0029F cc262

FC262N

L030010 dC40-20/3 :P35-0/37 :P35-0/38

-4-

WELDING OPERATION I N S T R U C T I O N S

8. §INGLE FUNCTION CHECE

U n i t i s now ready for operation, b u t p r ior to commencing weld- i n g , the following "functions check" i s recommended, switch on power source and check a i r flow. See t h a t a l l welding lead plugs are inserted i n the correct polarity sockets - electrode "posit ive", work "negative". Check a l l welding connections and plugs for tightness particularly "work" clamp.

Next ensure tha t a11 control cables and gas hoses are securely connected and tha t Gas Heater ( f o r C 0 2 only) i s plugged i n t o socket a t r e a r of power source. Switch on wire feeder, indic- a tor l igh t should now show "Power On". Open Gas cylinder f u l l y and check contents gauge for adequate gas supply.

Press "Gas Purge" switch and s e t gas flow i n accordance w i t h welding requirements, a t the same time check that gas f l o w i s adequate from gun nozzle. Set "wire speed" control to des i red wire speed Press ''wire inch" switch and check wire feed for correct pressure on drive rolls. Pressure should be suf- f ic ient to prevent any "s l ip" 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 i n accordance w i t h required voltage (see welding table),unit i s now ready for welding.

9. SETTING O F WELDING CURRENT AND VOLTAGE

Welding current i s determined automatically by the 'wire speed'. The electrode wire i s fed at the pre-selected speed by drive r o l l s through the gun cable t o the arc a t a constant speed, unchanged except when rese t 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 i s closed, i s divided into a number of steps by coarse selector and fine selector switches. The 'course' selector switch i s a combined high/low range ON/OFF switch working i n conjunction w i t h a "fine" selector switch giving 30 voltage steps.

The following sequence of weld se t t ing i s recommended:-

a ) Consu l t typical weld set t ing char t . b) Select welding current most suited to the application by following the settings of wire speed and voltage shown on the set t ing char t . To "tune" each weld sett ing, adjust wire speed only. c ) If voltage i s too low for the application, wire "stubbing" w i l l occur , par t icular ly a t s tar t of weld and weld contour w i l l be very convex. If the voltage i s too high, metal transfer w i l l be e r r a t i c w i t h excess spatter, d ) With welding current and voltage matched the resul t w i l l be an optimum tuned welding condition w i t h a smooth spatter-free arc.

I_

i;

8

0

W

DRAWING NO. CP25"'Ol 'ISSUE NO. 3 . -

- ITEM NO.

1 2 3 4 5 6 6 . 1 6 .2 7 8 9 10 l1 1 2 1 3 1 4 15 1 5 . 1 15.2 1 6 17 18 19 2 0 2 1 2 2 23 2 4 25 2 6 27 28 29 30 3 1 32 33 34 35 36 37

1-

PART NO.

CP 3 5 - 1.1 CP25-11 CP25-16 CP24-0/4 CP24-0/5 CP25-42 CP15-13/2 CP15-13/3 CP25-0/7 CP2-0/9 CP3-62 CP2-0/13 CP3-0/30 CP3-0/35 CP3-0/47 w1-22 W1-23 K 1 0

CP25-0/18 CP25-0/19 CP2-0/31 CP25-19 CP35-12 CP35-13 CP35-14/1 CP35-14/2 CP35-15 W I N 4 4 CP35-17 AM16 CP25-26 CP35-18 CP35-19 100293' TC262 TC262N 1030010 MC40-20/3 CP35-0/37 CP35-0/38

DESCRIPTION

Frame Assembly Transformer Assembly Inductance Assembly Fan Blade Fan Motor Rect i f ier Assembly Diode Diode C o n t r o l T r a n s f o r m e r Gas Heater P l u g R e c t i f i e r P r o t e c t i o n A s s e m b l y Welding Contactor Ammeter Shunt Ammeter 0-400 Amps. Voltmeter 0 - 6 0 V o l t I n d i c a t o r L i g h t Fuse Holders 3AG. 3A. Delay Fuse 3AG. 5A. Delay Fuse F i n e S e l e c t o r S w i t c h Coarse S e l e c t o r S w i t c h C o n t r o l P l u g F r o n t P a n e l Back P a n e l Top Cover L e f t Hand S i d e Cover R i g h t Hand S i d e Cover C o n t a c t o r a n d S w i t c h B a f f l e P l a t e Type No. S e r i a l No. Plate Terminal Assembly Ou tpu t Te rmina l s T rans fo rmer Suppor t T i e Bar Fan Mounting Bracket Eye N u t Gas O u t l e t F i t t i n g N u t f o r Above 3/4"W x 3" Hex. HD. S e t S c r e w . B a k e l i t e I n s u l a t o r s Loom Assembly Gas Hose