MODEL /oo - welding.com.au

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WELDING INDUSTRIES OF AUSTRALIA A DIVISION OF WELDING INDUSTRIES LTD

ABN 18 004547 111

Head Office and international Sales

5 Allan Street, Melrose Park

South Australia, 5039

Telephone (08) 8276 6494 Facsimile (08) 8276 6327

www.weldingindustries.com.au

[email protected]

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OWNERS MANUAL

SYNCHRO-PULSE CDT 450

MODEL NO. CP38-3, REV. G

1 1 /oo

QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICE 8 5 ?/I!: f

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SYNCHRO-PULSE CDT 450 MANUAL

SAFETY

Before this equipment is put into operation. the SAFE PRACTICES section at the back of the manual must be read completely . This will help to avoid possible injury resulting from unsafe work habits .

CONTENTS

Section Page

1 ............................... Introduction ................................................................. 3 2 ............................... Recelvmg ................................................................... 4 3 ............................... Specifications ............................................................. 4 4 ............................... Installation .................................................................. 5 5 ............................... Controls ...................................................................... 10 6 ............................... Normal Weld Sequence .............................................. 14 7 ............................... Welding Performance ................................................. 15

8 ............................... Overview .................................................................... 17

10 ............................. Other Fault Conditions ................................................ 26 11 ............................. Output Tests ............................................................... 27 12 ............................. Printed Circuit Boards ................................................. 28 13 ............................. Pads Lists ................................................................... 39

GENERAL . .

SERVICE INFORMATION

9 ............................... Fault Messages .......................................................... 19

APPENDICES 14 ............................. Weld Schedule List ..................................................... 49 15 ............................. Push-Pull Gun and Wirefeeder ................................... 54 16 ............................. Safe Practices ............................................................ 61

Figure Page

1 ............................... Supply Voltage Selection ............................................ 5 2 ............................... Cable and Hose Connections ...................................... 7 3 ............................... Cable Connections MMAW ......................................... 8 4 ............................... Cable and Hose Connections GTAW .......................... 9 5 ............................... Typical Arc Current Waveform ................................... 17

6 ............................... Functional Block Diagram ........................................... 18 7 ............................... Transistor Driver Assembly CP38-31 .......................... 22 8 ............................... Descriptive and Current Signal ................................... 29 9 ............................... Welding CPU Board CP38-10 ..................................... 30 10 ............................. Display CPU Board CP38-11 ...................................... 32

11 ............................. Transistor Driver Board CP38-12 ................................ 33 12 ............................. Background Driver Board CP38-13 ............................. 34 13 ............................. Wire/Gas Board CP38-16 ........................................... 35 14 ............................. Control Fuse Assembly CP38-17 ................................ 36 15 ............................. CDT 450 Circuit Diagram ............................................ 37

16 CDT 450 Assembly Diagram CP38-3 38 17 ............................. Main Switch Assembly CP38-21 ................................. 40 18 ............................. Keypad-Display Assembly CP38-50 ............................ 42

............................. ..........................

19 ............................. Rectifier Assembly CP38-51 ....................................... 43 20 ............................. Wirefeeder Assembly W35-0 ...................................... 44

21 ............................. W2-44 Two Roll Drive Assembly ............................... 45

24 ............................. AM223 Accessory Lead Kit ......................................... 48

26 ............................. Pull Gun Cable Assembly and Control Cable .............. 56 27 ............................. Hulftegger Gun Exploded View ................................... 57

29 ............................. Push Pull Wirefeeder Assembly W35-4 ...................... 60

22 ............................. Drive Roll and Wire Guide Table ................................ 46 23 ............................. Gun Cable Assembly BE2-441 OA ............................... 47

25 ............................. Cable and Hose Connections, Push Pull ..................... 55

28 ............................. Torch Neck Assemblies .............................................. 59

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SYNCHRO-PULSE CDT 450 MANUAL Paae 3 Y

The information contained in this manual is set out to enable you to properly maintain your new equipment and ensure that you obtain maximum operating efficiency. Please ensure that this information is kept in a safe place for ready reference when required at any future time.

When requesting spare parts, please quote the model and serial no. of the machine and part no. of the item required. All relevant part numbers are shown in lists contained in this manual. Failure to supply this information may result in unnecessary delays in supplying the correct parts.

1. INTRODUCTION.

The WIA SYNCHRO-PULSE CDT 450 is a multi-purpose arc welding power source providing for the following arc welding processes:

GAS METAL ARC WELDING (GMAW) is an arc welding process where an electrode wire is fed by motor driven rollers to a welding gun, and where D.C. welding current is supplied from the welding power source. The welding arc is struck between the work piece and the end of the wire, which melts into the weld pool. The welding arc is established in a gas shield of carbon dioxide or argon-rich mixed gases.

PULSED GMAW is an extension of the GMAW process offering improved arc transfer control. In Pulsed GMAW, the arc is supplied with D.C. welding current which is modulated between two distinct values. The lower level is referred to as the 'Background Current', and the higher level as the 'Pulse Current'. Under the influence of this pulsed current, the transfer of metal within the arc is ideally in the form of a single droplet, approximately the diameter of the electrode wire, which is transferred during the low energy period following each pulse.

PULSED GMAW is a full spray transfer process which is almost spatter free, producing weld deposits of smooth appearance with excellent penetration and sidewall fusion. The positive nature of arc transfer provides ease of puddle control in 'out of position' joints. The process expands the useful welding current range of a given diameter electrode wire. Only argon or argon-rich gases are used for pulsed GMAW.

MANUAL METAL ARC WELDING (MMAW) is a welding process where an arc is struck between a flux-coated consumable electrode and the work piece. The arc and the weld pool are both shielded by gases generated by the flux coating of the electrode.

GAS TUNGSTEN ARC WELDING (GTAW) is a welding process where the arc is struck between a non-consumable tungsten electrode and the work piece. A ceramic nozzle surrounds the tungsten electrode and directs a flow of inert gas, usually Argon, over the electrode and the weld zone. If filler metal is required, it is hand fed into the welding arc. The DC current arc of the CDT 450 is suitable for welding most ferrous and non-ferrous metals, but is not suitable for welding Aluminium for which an AC machine is required.


2. RECEIVING.

Check the equipment received against the shipping invoice to make sure the shipment is complete and undamaged. If any damage has occurred in transit, please immediately notify your supplier.

The SYNCHRO-PULSE CDT 450 package contains:

CP38-3 Power Source.

W35-0 Wirefeeder.

CP34-36 Remote Control pendant.

AM223-0/3 Inter-connecting Accessory lead kit, 3 metre.

w BE2-441OWlA BERNARD Gun cable, 3 metre.

Regulator and Flowmeter. (Argon)

(This) Owners Manual.

3. SPECIFICATIONS.

PRIMARY VOLTAGE ......................... 380, 415, 440 Volts A.C.,

EFFECTIVE PRIMARY CURRENT .... 25 Amps (at 415 Volts)

MAXUMUM PRIMARY CURRENT ..... 36 Amps (at 415 Volts)

Three Phase, 50 Hz.

OPEN CIRCUIT VOLTAGE ................ 70 Volts.

WELDING CURRENT RANGE ........... 35 -450Amps.

RATED OUTPUT (Note. 1) ................. 350 Amps, 100% Duty cycle

CIRCUIT BREAKER RATING ............. 32 Amps

FITTED SUPPLY CABLE ................... 56/0.30 Four Core, Heavy Duty PVC

450 Amps, 60% Duty cycle

WIRE SIZE RANGE ............................ 0.6mm - 2.4mm diameter.

WIRE SPEED RANGE ........................ A to q 6 Metredmin.

COOLING .............................................. cooled, air drawn in through rear fan grilles.

INSULATION ...................................... Class F, 115°C Rise.

DIMENSIQNS ..................................... 720mm H, 430rnrn W, 780mm L.

MASS ................................................. ~ 6 3 Kg

Note. l Duty cycle is defined in Australian Standard AS1966.A as the ratio of arcing time to 5 minutes in any 5 minute period, expressed as a percentage.


4. INSTALLATION.

A@€. Al1,electiical work shall only be undertaken by a qualified electrician. Before removieg any smachine,8covers,' ENSURE that the unit ,is disconnected from the electrical supbly.; f l ~ n the8~clnitl"is~energised LETHAL V,OLTAGES are present on these/ectricall cbrnponeots~~~encIoseti. 8 '

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- CONNECTION TO ELECTRICAL SUPPLY

The SYNCHRO-PULSE CDT 450 is supplied with a 3 metre, 4 core 56/0.30 Heavy Duty PVC Supply Flexible cable. The supply cable must be correctly connected to a suitable 3 Phase plug top or fixed connection point.

The minimum capacity of the mains wiring and power outlet supplying a welder is selected according to the effective primary current of the machine. The effective primary current for a SYNCHRO-PULSE CDT 450 is 25 Amps. The minimum recommended circuit breaker rating for a SYNCHRO-PULSE CDT 450 is 32 Amps.

The current rating of the mains cable depends on cable size and method of installation. Refer to AS/NZS 3008.1, Table 9. If it becomes necessary to replace the mains flexible supply cable, use only cable with correct current rating.

Access to the machine supply terminals is gained by removing the power-source side panel adjacent to the supply cable entry. Pass the replacement cable through the bush fitted to the machine back panel. The Earth wire (green / yellow) must be securely attached to the marked Earth stud. The three supply phases are terminated at the Main Contactor. Remove the contactor dust cover to gain access to the connection points. Ensure that the internal Brown and Blue loom wires remain connected to the 'live' side of the contactor. Tighten the cable clamp leaving sufficient slack in the cable such that the terminated wires are not in tension. SUPPLY VOLTAGE SELECTION

The SYNCHRO-PULSE CDT 450 is factory adjusted for a nominal electrical supply voltage of 41 5 volts, 3 phase, 50 Hz. The equipment is rated for variations of k IO%, that is voltages in the range 375 - 455V AC. If the voltage moves out of this range the machine will cease to weld, and will display an appropriate fault message. The local Supply Authority will usually make adjustments to correct for out of tolerance supply voltage, however if necessary the machine can be set to accept nominal input voltages of 380 or 440 Vac.

To change the supply voltage selection two separate transformers must be adjusted, and it is necessary to first remove both side panels.

I The Control Transformer terminal strip is located on the side of the machine nearest the Off / On switch. Move the Brown wire to the intended input voltage tapping.

adjacent to the Supply Flexible cable. Move the wire link to the intended input The Welding Transformer terminals are located on the side of the machine

voltage tappings. MAIN TRANSFORMER

1380 c L2 I '115 L': 440 l I 1

LINK A- BLt

CONTROL TRANSFORMER

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FIGURE l. SUPPLY VOLTAGE SELECTION.


CABLE AND HOSE CONNECTIONS - @MAW AND PULSED GMAW.

All Welding Current, Control and Shielding gas connections are shown in Figure 2. The cables and hoses are contained in the accessory kit AM223.

9 GAS. The accessory kit contains two gas hoses. The shorter length is used to connect the output of the gas regulator to the gas nipple on the rear panel of the CDT 450. The gas connector for the regulator end is included with the regulator.

The second hose is used to make the gas connection from the CDT 450 front pane! to the back panel of the W35 wirefeeder. Note that these connectors incorporate an 'OB ring seal and do not require excessive tightening.

CONTROL. Fit the Control Pendant and Wirefeeder cable male plugs into their respectively marked sockets on the CDT 450 front panel. Fit the Wirefeeder cable female plug into the socket at the rear of the wirefeeder.

WELDING CABLES. Bolt the lugged end of the wirefeeder welding cable plus the grey Arc Voltage Sensing wire to the brass gun adaptor of the two roll drive. Fit the cable clamp supplied. Attach the plug end to the Positive 'GMAW / PULSE' welding output socket of the power source.

plug end to the Negative 'COMMON' welding output socket. Connect the Work Clamp to the welding bench or work piece, and attach the

FITTING THE ELECTRODE WIRE Place the spool of electrode wire onto the spool holder. The location pin should

mate with a hole in the wire spool body. Fit the spool retaining 'R' clip supplied. Check the adjustment of the spool brake, which should be set to prevent over run

of the wire spool at the end of a weld, without unduly loading the wirefeed motor. The braking can be adjusted by rotating the Nyloc nut using a 15/16" AF or 24mm socket wrench.

Do not use dirty, rusty or kinked wire as it will not feed smoothly through the gun cable and will cause erratic welding. Deposits from contaminated wire will clog the gun cable liner requiring it to be replaced prematurely.

Check that the drive roller groove is correct for the electrode wire to be used. The drive roller part number is marked on the visible side of the installed roller. Refer to the drive roller selection chart in Figure 22. Check also that the correct size contact tip is fitted at the gun end. Refer to Section 13 for gun part numbers.

Open the two roll drive mechanism by rotating the compression spring assembly towards the front of the wirefeeder, allowing the upper roller housing to be lifted away from the driven roller. Straighten the end of the welding wire and pass it through the inlet guide, over the bottom driven roller and into the gun cable adaptor guide tube. Return the top roller to the closed position.


GAS CYLINDER & REGULATOR

REMOTE CONTROL PENDANT

'WORK' CLAMP

CONTROL CABLE W/F WELDING CABLE GUN CABLE ADAPTOR GREY VOLTAGE SENSE WIRE

u%!i !LmE 8 PIN PLUG

PLUG €!Lx & SOCKET WIRE FEEDER W35-0 E L GUN PLUG WELDING

& SOCKET - GUN

2 + TWO "3? RED "J (( S $ ~ & ~ t 3 t THREE '47 BLACK 4 + FOUR -i$r- BLACK 5 t FIVE \$ GREY - (VOLTAGE SENSE) 6 + SIX//6 7 t SEVEN /,7 8 t GREEN/YELLOW d8 SPARE

I t ONE -+ BLACK-

- (W/F MOTOR)

3 PIN 3 CORE PLUG m REMOTE CONTROL PENDANT

2 t BROWN - CURRENT 1 t BLUE - ARC LENGTH 3 t GREEN - COMMON 1 -'CURRENT'

'ARC LENGTH

FIGURE 2. CABLE AND HOSE CONNECTIONS, GMAW AND PULSED GMAW.

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CABLE CONNECTIONS - CONSTANT CURRENT MODES. All welding current and control connections for Constant Current modes MMAW

and GTAW are shown in below. The SYNCHRO-PULSE CDT 450 in Constant Current mode supplies DC (direct current) welding current to the arc. MMAW.

It is important to select the electrode polarity in accordance with the manufacturers' recommendations for that electrode. Both Positive electrode and Negative electrode methods of connection are shown in Figure 3. Some popular WIA AUSTARC electrodes are listed below with their recommended operating polarity. Austarc 12P, Classification AS1 553, E41 12.

A popular general purpose electrode used with ease in all positions, vertical up or down. The smooth forceful arc makes it an ideal electrode for all general mild steel applications. Preferred polarity electrode positive.

A smooth running electrode with a soft arc, particularly suited to light sheetmetal and smooth mitre fillet welds. Preferred polarity electrode positive.

A low hydrogen electrode with good arc stability and out-of-position welding characteristics. This electrode is ideal for medium carbon steels, or steels of unknown analysis. Operate electrode positive.

A high tensile (770 MPa), high chromium nickel electrode specially formulated for joining all alloy steels and irons, and for tool and die maintenance. Operate electrode positive.

Austarc 13S, Classification AS1 553, E41 13.

Austarc 16TC, Classification AS1 553, E481 6.

Unicord 31 2, Classification AS2576, 1330-A3

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When Constant Current mode schedules are selected, the Arc Length control is reconfigured as an output Off-On control switch. Rotate the potentiometer clockwise to energise the welding output, and anti-clockwise to de-energise the welding output.

ELECTRODE POSITIVE

OUTPUT ON

ELECTRODE NEGATIVE 1 l

n o ~ U U O

n o 1: 0 u n o o OUTPUT ON

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I FIGURE 3. CONNECTIONS FOR MMAW.

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SYNCHRO-PULSE CDT 450 MANUAL Paae 9 ~~

GTAW. For GTAW the torch is connected electrode negative. Figure 4 illustrates the

correct connection of the welding torch and gas supply utilising the CDT 450 internal gas valve.

Before initial use of the welding torch, allow gas to purge the torch and hoses for 5 minutes at approximately I O litreslmin. For welding purposes, the gas flow rate should be set in the range 2-5 litredmin.

Tungsten electrodes for DC GTAW should be l - 2% Thoriated. This type will provide the best arc initiation, arc stability and tip shape retention characteristics. Thoriated electrodes can be recognised by a red coded end. The tungsten electrode is ground to a point, with the grinding marks pointing towards the tip. For welding currents less than 20 amps, the included angle of the point should be 30°, for currents greater than 20 amps, the recommended angle is 60". When set in the torch, the tungsten should protrude 12mm from the ceramic gas nozzle.

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GAS CONNECTIQN (WHERE USED)

-0RCH SW. CONNECTION (WHERE USED)

TORCH SWITCH CONNECTION 1 ) 2 ) TORCH SWITCH 3)

8 PIN 4 ) PLUG 5 )

6 ) 7 ) 8 )

j FIGURE 4. CABLE AND HOSE CONNECTIONS FOR GTAW.

Paae I O SYNCHRO-PULSE CDT 450 MANUAL W

5. CONTROLS.

The SYNCHRO-PULSE CDT 450 power source is equipped with an operator keypad panel and a graphical display screen. All control facilities of the machine are accessed by use of the keypad. The individual key names and functions are:

SCHEDULE used to select a Welding Schedule; OPTION used to modify Weld and general purpose Options; ARROW KEYS used to position the highlight bar over a menu item. ENTER used to select the menu item; HELP used to view 'Help' information for the current menu; INCH used to Inch the electrode wire forward; PURGE used to Purge the shielding gas hoses.

The display screen provides information such as: The selected Weld Schedule or Process; The selected wirefeed rate; The estimated welding current; Actual weld current and voltage during welding; Average weld current and voltage during the last weld; Advice of any detected fault condition.

When the machine is first energised, the screen briefly displays the WIA logo during which time the microprocessor circuits are performing self-test routines. When these checks have been completed, and provided that no fault conditions exist, the screen will display information simitar to that shown below. For assistance with fault messages, refer to Section 9 of this manual.

#l97 85.9 ER316L 8.8 STAINLESS 316L GAS: ARGON +5#t HE + 2 C& 'IRE 5 . 2 mlmin CURRENT:

APPROX. FEED : 75 i p s

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The display indicates the presently selected Weld Schedule with its internal library number, the recommended gas composition, the set wirefeed rate, the estimated welding current and an Arc Length setting indicator. This is referred to as the 'Ready' state, as the machine is ready to weld with the settings displayed.

SYNCHRO-PULSE CDT 450 MANUAL Paae l l ~~ v

TO SELECT A WELD SCHEDULE. From the SCHEDULE menu, GMAW, Pulsed GMAW, MMAW and GTAW

schedules can be selected. The Pulsed GMAW Weld Schedules available have been established for specific combinations of electrode wire type, wire diameter, and shielding gas mixtures. More than 100 combinations are available in the CDT 450 library. It is important that the correct Weld Schedule be selected for the consumables (wire and gas) in use.

Press the SCHEDULE key. The screen will display a list of weld schedule groups beginning with electrode types for Pulsed GMAW. Use the ARROW keys to position the highlight bar over the required group, then press ENTER. When 'on-line' programming, Weld Schedules sent to the machine from a separate programming device are accessible through the DOWNLOAD group. - 1 Choose ELECTRODE TYPE required:

EPROM : COPPER & ALLOYS #33 125 FLUX CORED WIRES #3##07

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Use the ARROW keys to highlight the required schedule, then press ENTER.

1.2rnrn STRINLESS 318 A5.9 ER318 8.9mrn STAINLESS 312 A5.9 ER312

0.9mrn STAINLESS 316LSi BHP 3CR12 plutle I I

Section 14 of this manual lists all of the Pulsed GMAW weld schedules currently available in the CDT library, together with their individual schedule numbers. In addition to the method described above, weld schedules may also be selected directly by number. This feature is available as the last item in the SCHEDULE menu. When this mode is in use, the screen will initially display the number of the currently selected weld schedule. Using the ARROW and ENTER keys, index each digit to show the number of the new schedule required, then press ENTER. OPTIONS

The OPTION menu provides two groups of Options as shown below. The first group of Weld Options are specific to the selected Weld Schedule, providing adjustment of:

Pre-gas time; w Creep speed;

Crater-fill time; Burn-back time; Post-gas time.

The remaining options are not specific to the selected Weld Schedule, and provide the following features:

Recall of the last weld Current and Voltage data;

Selection of standard or latching gun-switch modes; Servicing tests; Demonstration display.

l Recall of the last Fault message;


TO ADJUST AN OPTION. Press the OPTION key. The screen shows a menu of available options.

Chum OPTION TYPE to. be chunged:

POST-GAS - gus flow time ufter welding I I

Use the ARROW keys to highlight the desired Option, then press ENTER. For Weld Options, the screen now shows a list of time periods appropriate to the

Option, with the default, or the last value selected already positioned in the highlight bar. Use the ARROW keys to highlight the required new value, then press ENTER.

"

[how vulue far CRATER-FILL durutiw: I nil seconds

1.2 seconds 1.5 slecclnds

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Adjusted Weld Option values become part of the selected Weld Schedule. The SYNCHRO-PULSE CDT 450 stores all Weld Option settings for the last 16 Weld Schedules used, and automatically applies the adjusted values whenever one of these schedules is selected.

The remaining Options provide the following facilities:

INFORMATION. Display of Current and Voltage data relating to the last weld performed. The figures are averages taken over the last one second of the weld, excluding Crater-fill and Burn-back periods. Press any key to exit from this display.

FAULT. To assist with fault finding, selection of this option will re-display the last fault message. Press any key or the gun switch to exit from this option.

GUN SWITCH. This option provides a choice between 'Normal' and 'Latching' modes of gun-switch operation. When Latching is selected, the gun switch must be closed then released to start the weld, then closed and released to end the weld. This is intended to reduce operator fatigue during long welding periods.

SERVICE. Selection of this option will display a menu of special facilities available to assist a Service person. Each is described in the relevant sections of this manual.

DEMONSTRATION. Selection of this option will initiate a graphical, non welding demonstration of the features of the SYNCHRO-PULSE CDT 450. Hold down any key to exit from the demonstration.


REMOTE CONTROL PENDANT

welding process. GMAW AND PULSED GMAW

The remote control pendant has differing functions depending on the selected

CURRENT. This potentiometer control sets the wirefeed rate, which in turn fundamentally determines the welding current. The SYNCHRO-PULSE CDT 450 internally adjusts other welding parameters in accordance with the setting of this control.

The dial is a ten-turn vernier device which is graduated from 0 to 10.00. The graduations do not directly relate to any welding parameter, however the setting of this control is indicated by the wirefeed rate and estimated welding current information displayed when the machine is in the 'Ready' condition.

ARC LENGTH. This potentiometer control allows 'fine tuning' of the arc length to suit the welding requirement. The most ideal welding conditions are normally achieved when the operating arc length is adjusted to be as short as practicable, while maintaining a stable welding arc. An occasional short circuit associated with a crackle sound is acceptable. The setting of this control is indicated in five steps of positive and five steps of negative adjustment by the display when the machine is in the 'Ready' condition.

Changes to the weld preparation and/or work piece temperature may require adjustment of the arc length in order to maintain these conditions.

CONSTANT CURRENT MODES - MMAW AND GTAW CURRENT. This control sets the output welding current directly within the range of the selected Constant Current schedule. The estimated welding current is displayed when the machine is in the 'Ready' condition.

ARC LENGTH. Arc length control is not appropriate to MMAW and GTAW which are both Constant Current welding processes. When these schedules are selected, the Arc Length control is reconfigured as an output Off-On control switch. Rotate the potentiometer clockwise to energise the welding output, and anti-clockwise to de-energise the welding output. Alternatively, a torch switch may be connected as shown in Figure 4.

INCH AND PURGE. The INCH and PURGE keys may be used during the 'Ready' state. The selected

function is active while the key is pressed. INCH runs the wirefeed motor to feed electrode wire through the gun cable without

applying welding potential to the wire. If INCH is pressed momentarily, small increments of wire are fed. If the key is held down, the motor will accelerate to the welding wirefeed speed as set by the CURRENT potentiometer. For maximum inching speed, press the INCH and UP ARROW keys simultaneously. During inching, the intended speed of the wirefeed motor is displayed in rpm.

PURGE energises the gas valve to fill the gas hoses with shielding gas, or to allow adjustment of the gas flow rate. During PURGE, the display indicates a recommended range of gas flow rate, plus some commercial names for the gas mixture required for the currently selected Weld Schedule.


HELP KEY. At any stage of operation of the CDT 450 (except during welding), the HELP key

may be pressed to display additional information relating to the present operating mode of the machine. To exit from each message, press the HELP button a second time. STANDBY MODE.

The SYNCHRO-PULSE CDT 450 incorporates a power-saving standby mode. If the machine is left idle for more than 25 minutes, the welding transformer and cooling fans are de-energised and a 'Standby' message is displayed. Use of the keypad or gun switch will return the machine to normal operation.

6. NORMAL WELD SEQUENCE.

GMAW AND PULSED GMAW

WELD START.

The gas valve opens allowing shielding gas to flow for the selected Pre-gas time;

Welding voltage is applied between the electrode wire and the work piece;

Wirefeed commences at creep speed;

The wire contacts the work piece, and the arc is established. Wirefeed steps to run speed as determined by the setting of the remote Current control.

During welding, the screen displays information similar to that shown below. The actual arc voltage and current is displayed both as a digital number, and in bar-graph form.

L

8.9 AUSTMIG 316LSi 135.9 ER316LSi

24 V 0 l I 1 S 1 1 1 1 1 1 1

10 20 30 40 50

75 fi B 1 8 8 288 3aa 488 588 I n l 1 1 1 1 1 1 s 1

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WELD END.

If a non-zero value of Crater fill has been selected, the wirefeed motor slows over the time period selected;

The wire drive motor is dynamically braked to a stop;

Welding voltage is held 'On' for the selected 'Burnback' time. Burnback ensures that the electrode wire does not freeze in the solidifying weld pool.

The gas valve is held 'On' for the selected Post-gas time. Post-gas allows the

After welding, the screen displays information relating to the last weld. The

molten weld pool to solidify before exposure to atmospheric gases.

Current and Voltage figures shown are averages taken over the last one second of the last weld excluding crater-fill and burnback periods. The information is displayed for I O seconds, or until a key is pressed. The same information can be recalled by selecting OPTION > INFORMATION.

SYNCHRO-PULSE CDT 450 MANUAL Page l 5

7. WELDiNG PERFORMANCE.

GMAW AND PULSED GMAW. GMAW equipment can only provide optimum results if all external components are

correctly installed, adjusted, maintained, and the correct consumables are being used. In a situation of unsatisfactory welding results, the welding power source is often the first item suspected, however the fau!t frequently lies in these more routine areas. SHIELDING GAS

In GMAW, and especially Pulsed GMAW, the shielding gas composition plays a most important part in establishing correct arc behaviour.

Each SYNCHRO-PULSE CDT 450 pulsed weld schedule has been established for use with a specific gas mixture. It is important that the gas mixtures recommended be adhered to. The gases specified are all Argon rich, and in some cases are 100% Argon. Carbon Dioxide gas alone is not suitable for pulse welding, but it is a component in mixtures used for several applications, and can be used for non-pulsed G.M.A.W.

One function of the shielding gas is to protect the molten weld pool from the effects of oxygen in the atmosphere. Without this protection the weld deposit becomes 'honeycombed' in appearance, an effect which is described as weld porosity.

In draft-free conditions the gas flow rate required to give adequate protection is typically 10 litres/min. In situations where drafts cannot be avoided, it may be necessary to increase this rate and/or to provide screening of the work area. Holding down the PURGE key will display a recommended minimum gas flow rate for the selected schedule.

If weld porosity occurs:

Remove spatter build-up from inside the gun nozzle. Check for fraying of the internal nozzle insulator, and replace the nozzle if necessary.

w Check that the gas hoses have not become cracked or frayed, and that the rubber seals in each gas connection point are not broken or perished.

Check the gas flow rate at the nozzle, and compare this reading with the flow rate at the regulator. A discrepancy may indicate a previously undetected gas leak.

WIREFEED In any GMAW process, the electrode wirefeed must be smooth and constant in

order to obtain the most satisfactory welding results. It is important to observe the following points:

Minimise the build up of dirt, dust and swarf in the gun cable liner by the use of clean electrode wire. Ensure that the compression force of the drive rollers is not excessive, and that the rollers have been correctly selected for the welding electrode in use. For drive roll data, refer to Figure 22 of this manual.

The gun cable liner must be correctly fitted so that the free end seats firmly into the back of the welding gun head. In this way the electrode wire is supported and guided directly into the welding tip. Refer to Section 13 for liner fitting instructions.

Replace the welding tip as it becomes worn.

Check that the electrode wire spool holder rotates smoothly and that the braking action is not excessive.

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Page l 6 SYNCHRO-PULSE CDT 450 MANUAL

ARC LENGTH. The most ideal pulsed GMAW welding conditions are achieved when the arc length

is adjusted to be as short as possible while maintaining a stable spray mode of welding arc. Occasional arc short circuiting, associated with a crackling sound, is acceptable. Changes in weld preparation and/or work piece temperature may require adjustment of the arc length to maintain these conditions.

If the arc length is too short, it will result in excessive crackle, shorting and spatter, while if too long may result in weld undercut and lack of weld penetration. SURFACE CONTAMINATION.

Surface contamination of the work piece with water, oil, grease, galvanising, or paint can often cause severe disruption to the arc. Gases generated can contaminate the shielding gas, and may affect the chemical composition of the weld. It is normally a requirement to clean the surface with a suitable solvent or by linishing or grinding. ARC BLOW.

Arc blow occurs when a magnetic field distorts or extinguishes the welding arc. The magnetic field is usually the result of welding current passing through the object being welded or through adjacent steel clamp bars. This is most often seen when welding steel sections, and particularly where there is a root gap or at the extreme end of a section. Arc blow can also result from the use of magnetic clamps.

Arc blow can be difficult to overcome, however the following steps have been found useful:

Re-position the Work clamp on the work piece. It is usually best to weld towards the clamp;

If possible, bridge the end of a gap with a heavy tack weld or backing bar. Weld towards the bridge;

m Isolate clamp bars from the welding current path;

Remove magnetic clamps;

Use non-magnetic materials for welding fixtures.

SYNCHRO-PULSE CDT 450 MANUAL Paae 17 ~ -~~ - . ~

~~- -

SERVICE INFORMATION.

CONTROL CIRCUIT MAINS FUSES

The supply circuit to the Control Transformer is protected by two H.R.C. fuse links. These fuses are located inside the power source and are only accessible by removing the right hand side panel.

8. OVERVIEW OF PULSED GMAW.

When set for pulsed GMAW, the SYNCHRO-PULSE CDT 450 supplies to the

l. Current pulses of controlled amplitude, time duration and frequency. 2. Controlled amplitude background current. Typical value ranges for these parameters are:

welding arc a DC current comprising two distinct elements. These are:

Pulse current peak: 200 - 600 amps;

w Pulse width: 2 - 5 mS;

Pulse frequency: 30 - 400 Hz;

Background current: 12 - 75 amps average.

/- 'WINDOW' UPPER

1 1 I

'WINDOW' LOWER I ,

/ CURRENT PULSE

BACKGROUND CURRENT

/- 'WINDOW' UPPER

1 'WINDOW' LOWER

/ CURRENT PULSE

I \ BACKGROUND CURRENT

I h a J 4-w

1 1 I

I ,

I Y

FIGURE 5. TYPICAL ARC CURRENT WAVEFORM.

~ Paae 18 SYNCHRO-PULSE CDT 450 MANUAL Y

The individual pulse and background parameters, plus pulse frequency, wirefeed, arc voltage and other data have been predetermined to suit the welding electrode and shielding gas combination. These parameters together are referred to as a 'Weld Schedule'. The SYNCHRO-PULSE CDT 450 has an internal library of over 100 weld schedules, allowing Pulsed GMAW using a wide range of electrode wire types, wire diameters and shielding gas combinations.

The pulse and background currents are both derived by 'switch-mode' control. In this technique, the welding current is repeatedly switched On and Off in such a way that the current is held within a specified 'window' range.

The SYNCHRO-PULSE CDT 450 has separate switches for pulse and background current. The pulse current switch is a bank of three high current bipolar transistors mounted on a fan cooled, monolithic heatsink. The background switch is a bank of three Mosfet transistors. The basic D.C. welding current is the rectified and filtered output of a three phase welding transformer.

Central to the CDT 450 is a microprocessor based control circuit CP38-10. This circuit takes input from the press button keypad and remote control pendant, plus current and voltage feedback from the arc, and in turn controls the drivers for each of the current switches. The circuit also manages the flow of shielding gas, wire feed and feed rate and sends data to the graphical display.

The block diagram illustrates the connections between the control blocks of the SYNCHRO-PULSE CDT 450.

DISPLAY I

Y REMOTE CONTROL

I DlSpBLoAAvR~PU b I PRESS-BUTTON

CP38-11 KEYPAD M I I

t I I

ARC CURRENT FEEDBACK

t * BACKGROUND * DRIVER BOARD b CP38-13

WELDING CPU BOARD CP38- 10

ARC VOLTAGE k

FEEDBACK TRANSISTOR + DRIVER BOARD

t CP38-12 I

GUN SWITCH

WIREISAS CONTROL BOARD

CP38-16

WIREFEED MOTOR

FIGURE 6. FUNCTIONAL BLOCK DIAGRAM.

i i


9. FAULT MESSAGES

The SYNCHRO-PULSE CDT 450 has means to detect a variety of external and internal fault conditions. If a fault is detected, the machine will cease welding and display a fault message similar to that shown below. Each message includes a description of the fault condition, a fault code number and suggested actions to assist with fault correction.

* Check plug P3 Q ~ I Weld CPU CP38-l#. I

FAULT - R&e Pendud DiSCDnnECtEd I # Check that the control pendant plug

is correctly inserted) and t ha t the cuble is not damaged.

$ Tt-y another control pendant.

l I

Fault messages are displayed in order of priority. If two or more faults occur simultaneously, the fault of highest priority will be displayed first. Following correction of that fault, the next highest priority fault will be displayed. In the following list, the faults are given in descending order of priority.

Fault messages are displayed when a fault condition exists, or if the 'Display last fault message' Option has been selected. This feature may be used to assist detection of intermittent faults. The Schedule and Option menus may still be accessed when a fault exists, but the machine will not permit welding.

Diagrams for all circuits and printed circuit boards referred to may be found in the next section of this manual.

Fault No. Fault Message Page

1 .............................. Display CPU Memory Problem' .................. 19

3 .............................. Output Terminals Live' ............................... 20

6 .............................. Supply Phase Failure' ................................ 23 7/8 .......................... 'Supply High / Supply Low' ......................... 23

2 .............................. Welding CPU Not Responding' .................. 20

4 ............................. .CPU Board Power Supply' ......................... 20 5 .............................. Transistor Driver Power' ............................. 21

9 ............................ .'Background Driver Power' .......................... 24 10 ........................... 'Overcurrent Detected' ................................ 24 11 ............................ Thermostat Overheated' ............................. 24 12 ........................ ...' Arc Voltage Sensing Problem'.. .................. 25 13 ........................... 'Wirefeed Control Problem' ......................... 25 14.. .......................... Remote Pendant Disconnected' ................. 26 15 ...................... .....' External Detection Input' ............................ 26

'DISPLAY CPU MEMORY PROBLEM' This message results from two possible conditions relating to the Display CPU

Assembly CP38-11. The first is an incorrect checksum result obtained during the power- up sequence which indicates corruption of the Eprom data. The second is failure of the RAM read/write power-up test.

Fit a new Eprom to the CP38-1 l board. Refer to Section 12 of this manual for fitting instructions.

Replace the complete printed circuit assembly CP38-11.

I

Paae 20 SYNCHRO-PULSE CDT 450 MANUAL Y

'WELDING CPU NOT RESPONDING' The SYNCHRO-PULSE CDT 450 has two microprocessor based control circuits.

These are the Welding CPU Board CP38-IO, and the Display CPU Board CP38-11. The two circuits communicate via a serial data link. This fault message indicates a failure of the two boards to establish correct communications.

w Check that the connecting cable between the CP38-11 and CP38-10 boards is

Confirm that the microprocessor of the Welding CPU board CP38-10 is

correctly fitted, and that the plugs and sockets are not damaged.

functioning correctly. This is indicated by regular flashing of the 'Beacon' LED 4. If it is not:

Check that the CP38-10 power supply indicators LEDI, LED2, and LED3 are each lit. If any are not, refer to the information below for the fault message 'Circuit Board Power Supply'.

the numbers '380', and that it is correctly fitted.

instructions.

this manual for fitting instructions.

w Confirm that the CP38-10 has an Eprom with a code number beginning with

Fit another known good Eprom. Refer to Section 12 of this manual for fitting

Replace the complete Welding CPU board CP38-10. Refer to Section 12 of

Replace the Display CPU Board CP38-11. 'OUTPUT TERMINALS LIVE'

If the CDT 450 detects voltage across the output terminals at a time when the machine is not being instructed to weld, failure of internal components is presumed and so the machine defaults to a safe condition by de-energising the welding transformer supply contactor. This fault message can only be reset by switching the power source Off.

Inspect the output transistors of the Transistor Switch Assembly for damage. Using an ohmmeter, ensure that the transistor collector / emitter junctions are not short circuited. If any components have failed, the complete Transistor Switch Assembly CP38-21 must be replaced. Refer to Figure 17.

'CPU BOARD POWER SUPPLY.' This fault message is displayed if a Welding CPU onboard power supply is not

available. The supplies are each powered from electrically isolated control transformer windings which are individually fused on the Control Fuse Assembly Board CP38-17. The table below relates each power supply to its LED indicator number and fuse number.

CP38-10 CP38-17

CPU +5v LED 3 Fuse F7 CPU -15V LED 2

Fuse F5 CPU +15V LED l Fuse F6

SHUNT AMP +/-l 5V No LED Fuse F4

l l


Establish which power supply has failed by inspection of the LED indicators. Check the appropriate CP38-17 fuse, and replace as required with a l .6 Amp type M205 fuse. If no fuses have failed:

= Check for correct AC voltage from each control transformer winding, and trace each supply to the CP38-10 board. Refer to the circuit diagram Figure 15. Repair or replace loom or control transformer as required.

Refer to Section 12 of this manual for fitting instructions. = If all AC supplies to the CP38-10 are correct, replace the CP38-10 board.

FAULTS DETECTED BY TRANSISTOR DRIVER BOARD CP38-l2 The output transistors of the Transistor Switch Assembly are controlled by the

Transistor Driver Board CP38-12, in conjunction with some off-board components. This assembly is mounted on the right side (when facing the front of the CDT) of the Transistor Switch Assembly CP38-21.

The driver circuit includes means for detecting four separate fauit conditions which are listed below in descending order of priority. If any fault is detected, onboard hardware prevents further operation of the transistors, and signals the fault to the Welding CPU Board CP38-IO. The four fault status lines to the Welding CPU Board, labelled in circuit diagrams 'ERR TS', 'ERR VL', 'ERR VH', 'ERR PF', are failsafe current loops, ie current flow = OK. 'TRANSISTOR DRIVER POWER

This fault message results from failure of any of the three onboard power supplies of the Transistor Driver Board CP38-12, and is signalled on the status line 'ERR TS'. These are +1OV DC (high current) and +1QV DC (control) supplied from the three phase welding transformer auxiliary windings, and -1OV DC supplied from a control transformer winding via the Control Fuse Assembly CP38-17.

Check to establish that the welding transformer contactor is energised. If not: Check 24Qv fuse marked 'FANS' located behind the hinged front panel. Inspect the wiring from connector P8 of the Welding CPU board CP38-IO to

Check for contactor coil continuity. the solid-state contactor control relay.

Check CP38-17 fuse F1 and replace as required with a 1.6 amp, type M205 fuse. Test for 8V AC supply voltage between the CP38-12 loom terminals marked '8Vac'.

Check the 20A 3AG fuse which is part of the Transistor Driver Assembly CP38- 31. If it has ruptured:

= Inspect the external driver wiring, transistors H6 and H7, and the three main switching transistors for damage. If any of these components have failed, the complete Transistor Switch Assembly CP38-21 must be replaced. Refer to Figure 17. Replace the fuse. Use only a 20 Amp, 3AG, standard action type. If the replacement fuse also ruptures, assume component failure of the CP38-21 Transistor Switch Assembly which must then be replaced as above.

With the machine energised, test for approx. 1QV DC across capacitor C20, reference Figure 7. If 1OV DC is not available:

SYNCHRO-PULSE CDT 450 MANUAL v

Check for 8 V AC supply to the three phase rectifier. This voltage is supplied from auxiliary windings of the welding transformer, and should be available whenever the machine is energised. Test both external diode bridges.

d

FROM MAIN WELDIF TRANSFORMER

AUXILLIARY

dG

FIGURE 7. TRANSISTOR DRIVER ASSEMBLY CP38-31.


'SUPPLY PHASE FAILURE'

phase of supply voltage, and is signalled by the status line 'ERR PF'. This fault message results from the CP38-12 board detecting the absence of one

Check supply at the 3 phase power outlet. If one phase is not available at this

Check the supply fuses at the building electrical distribution board. 9 Check wiring of the three phase power outlet.

point:

Check wiring of the three phase plug top, and inspect the supply flexible cable for damage.

w With the machine powered OFF, test for three phase supply at the input side of the machine contactor.

Check that the welding transformer primary voltage selection links are securely

Test for 8 V AC between CP38-12 pins A,B and C. If one phase is not available,

Replace the CP38-12 board. 'SUPPLY HIGH 1 SUPPLY LOW

These fault messages result from the CP38-12 board detecting the electrical supply voltage outside of an acceptable range. High voltage is signalled on status line 'ERR VH', and low voltage on 'ERR VL'. The acceptable range is +IO% of the setting of the welding transformer primary voltage selector.

fitted.

inspect the loom wiring to these points.

Check the selected welding transformer primary voltage. For Australian use, the standard setting is 41 5 Volts.

Measure the actual value of the primary supply voltage. The voltage will be lowest when the machine is delivering welding current, due to volt drop in building wiring and supply cables. If the voltage is outside of the acceptable range, it may be necessary to consult with your local Power Supply Authority. Alternatively, a more suitable primary supply voltage may be selected for the control and welding transformers. Refer to Section 4 of this manual.

NOMINAL SUPPLY ACCEPTABLE LOW ACCEPTABLE HIGH VOLTAGE VOLTAGE VOLTAGE

I I 380 41 5 440

345 375 395

41 5 455 485


'BACKGROUND DRIVER POWER' The Background transistor switch is controlled by the Background Driver Board

CP38-13. This assembly is mounted with the transistor heatsink on the left hand side (when facing the front of the CDT) of the Transistor Switch Assembly CP38-21. The driver circuit includes means for detecting failure of the on-board +20V DC power

If a fault is detected, on-board hardware prevents further operation of the transistors, and the fault is signalled to the Welding CPU Board CP38-IO. The status line labelled 'ERR BG' in circuit diagrams is a failsafe current loop, ie. current flow = OK.

supply.

Check CP38-l7 fuse F2.

w Check for 15V AC between the loom terminals marked 15 VAC.

Replace the complete Background Switch Assembiy CP38-32. 'OVERCURRENT DETECTED'

This fault message is displayed if welding current which exceeds the ratings of the CDT 450 is detected. Due to the design of the shunt signal amplifier circuit, this message is also displayed should the shunt wires become broken or otherwise disconnected. This is an important safety feature of the machine, because without the shunt connected, the machine has no ability to regulate arc current.

Has the machine been used in excess of its ratings? If so, modify the pattern of use.

Is a non-standard schedule (i.e. from the Download menu) in use? If so, the weld

Ensure correct termination of the red and black twisted pair of shunt wires.

Did the welding current and arc length become uncontrolled at the time of failure? If yes, it is possible there has been a major failure of CDT components. Inspect the components of the Transistor Switch Assembly CP38-21 and the Welding CPU Board CP38-10 for indications of breakdown.

parameter data may be corrupted or incorrectly specified.

'THERMOSTAT OVERHEATED' The SYNCHRO-PULSE CDT 450 has thermostats attached to the welding current

Rectifier Assembly CP38-51 , and to the Transistor Switch Assembly CP38-21, each assembly having an integral cooling fan. The thermostats are normally closed contacts. Via this circuit 12 V AC is applied between CP38-IO connector P6, pins 5 and 6.

m If the CDT 450 has been operating in excess of its ratings or with restricted

Remove any obstacle to free airflow through the machine. Inspect for airflow, leave the machine energised so that the internal fans will assist cooling.

excessive dust build up inside the machine. Remove dust with a moderate jet of dry compressed air.


Check that both fans are rotating. If both are stationary: Check the fan fuse located behind the hinged front panel. If the fuse is ruptured, inspect for cause of overload. Check both fans are free to rotate, and that fan wiring is not damaged. Fit a replacement fuse, l .5A type 3AG. . Check for 240V AC available from control transformer.

If one fan is stationary: Test for 240V AC supply to the fan motor. Replace fan motor as required.

w Check CP38-17 fuse F3, which is the fuse for 12 V AC. If it is ruptured, the gun

Test both thermostats for electrical continuity. ‘ARC VOLTAGE SENSING PROBLEM’

The SYNCHRO-PULSE CDT 450 employs arc voltage feedback to enable the control system to regulate the arc length when welding in GMAW and Pulsed GMAW modes. The arc voltage is detected at the wirefeeder/gun cable connection, and is wired to pin 5 of the wirefeeder control socket. While in the ‘Ready’ state, the CDT 450 checks for continuity between the positive welding output terminal and pin 5, and will signal a fault condition if this loop is broken. Continuity is not checked when a Constant Current mode is selected, as arc voftage detection is not required.

switch relay, (which is part of the WireiGas Board CP38-16), also will not operate.

Check that the wirefeeder control cable is correctly inserted into the CDT

Check that the positive welding lead is correctly inserted into the positive GMAW

Inspect the wirefeeder to ensure that the grey arc voltage sensing wire is not

Inspect the internal terminations of the wirefeeder control plug. ‘WIREFEEDER CONTROL PROBLEM’

The Wire/Gas Board CP38-l6 has an on board power supply for + l2 and +24V DC. If the power supply is not available, this is signalled to the Welding CPU Board CP38-10 via a failsafe current loop, labelled in circuit diagrams ‘ERR WF’.

Check the wirefeeder fuse which is located behind the hinged front panel. If it has

Investigate cause of fuse failure, eg: wirefeeder control cable damage or seized wirefeed motor. Replace the fuse only with a 10A 3AG standard action type.

Test for 30V AC between the two heatsinks of the Wire/Gas Control Board CP38-

wirefeeder control socket.

/ PULSE welding output terminal.

broken or disconnected.

ruptured:

16. If this voltage is not available, test for continuity back to the control transformer.

Test for 30V AC at the control transformer terminal strip.

Replace the Wire/Gas Control Board CP38-16.


'REMOTE PENDANT DISCONNECTED' The remote control pendant is wired as two 10 mA constant current loops sharing a

common return wire. According to the setting of the two potentiometers, a voltage in the range 0 - 10 volts is dropped across each. If either of the current loops is broken, the CDT will signal a fault condition. Each current loop has an LED continuity indicator located on the Welding CPU Board CP38-IO. LED 5 is for the 'CURRENT' loop, and LED 6 for the 'ARC LENGTH' loop. LED lit = circuit OK.

Check that the pendant control plug is fitted to the pendant socket.

Inspect the pendant cable for damage.

Fit another pendant. 'EXTERNAL DETECTION INPUT'

The Welding CPU Board CP38-IO has a spare fault input which may be connected to external equipment. The CDT is supplied with these connections internally by-passed.

I O . OTHER FAULT CONDITIONS.

BLANK DISPLAY If the Display is completely blue showing no white characters, a problem with the

display screen biasing is indicated. This may be due to incorrect setting of the Display Contrast adjustment, or to failure of the -1 5V DC power supply of the Display CPU Board CP38-11.

Note the present setting of the Display Contrast potentiometer. Adjust the potentiometer, however if this does not correct the fault, return it to the original setting.

Check Fuse F6 of the Control Fuse Assembly CP38-17.

Check for -2OV DC supply between pin 7 (neg.) and pin 6 (common) of connector P1 of the Display CPU Board CP38-l l . This supply is taken from the Welding CPU Board CP38-10.

Replace the Display CPU Board. BLANK DISPLAY WITH WHITE LINE

supply of the Display CPU Board CP38-11 is probable. If the display is blue with a white stripe across it, failure of the +5V DC power

I Check fuse F7 of the Control Fuse Assembly CP38-17.

Check for + l OV DC supply between pin 1 (positive) and pin 6 (common) of connector P1 of the Display CPU Board CP38-11. This supply is taken from the Welding CPU Board CP38-IO.

Replace the Display CPU Board.

~

SYNCHRO-PULSE CDT 450 MANUAL Paae 27 U

DARK DISPLAY If the display is dark with a faintly visible message, the fluorescent backlight tube is

not operating. The tube is powered by an inverter which is driven by +20V DC supplied from the Welding CPU Board CP38-10.

Check that the white 'Lamp' connector is correctly fitted to the mating connector

Check fuse F5 of the Control fuse Assembly CP38-17.

Check for +20V DC supply between pin 8 (positive) and pin 6 (common) of

Replace the Display CPU Board.

which is part of the Display CPU Board CP38-1 l.

connector P1 of the Display CPU Board CP38-11.

11. OUTPUT TESTS

The OPTION menu of the CDT 450 includes two 'test' schedules which allow isolated checking of the Pulse and Background output currents of the machine. BACKGROUND CURRENT TEST

For this test, first feed approximately 500mm of electrode wire from the gun and connect the end of it to the welding work piece. This wire will act as a temporary load resistor for the CDT 450.

Set the 'Current' control to '0.0, then select OPTION > SERVICE > BACKGROUND. Close the gun switch. Approximately 15 Amps should now be flowing in the welding circuit and be indicated on the display screen. Increasing the setting of the 'Current' control should increase the output current up to a maximum of 30 Amps. If the above occurs as described, the background circuit is functioning correctly. PULSE CURRENT TEST

As above, first feed approximately 500mm of electrode wire from the gun and connect the end of it to the welding work piece.

Set the 'Current' control to 'O.O', then select OPTION > SERVICE > PULSE. Close the gun switch. Approximately 8 Amps should now be flowing in the welding circuit and be indicated on the display screen. Increasing the setting of the 'Current' control should increase the output current up to a maximum of approximately 39 Amps. If the above occurs as described, the pulse current circuit is functioning correctly.

When these tests have been completed, re-select the required Weld Schedule.

l ~

~

1

1

Paae 28 SYNCHRO-PULSE CDT 450 MANUAL v

12. PRINTED CIRCUIT BOARDS.

WELDING CPU BOARD CP38-10 This board is a microprocessor based control circuit which is dedicated to

Receives serial transmissions from the Display CPU Board defining the selected

Reads the remote control pendant settings.

Monitors arc current and arc voltage.

Controls the Pulse and Background transistors to form the welding current.

Outputs wirefeed run/stop and speed information, plus gas on/off commands to

management of the welding arc. It performs the following circuit functions:

Weld Schedule and Options.

the Wire/Gas Control board.

Reads all fault status lines.

m Sends serial telemetry to the Display CPU Board for information to be displayed, eg: arc current and voltage, welding status, fault status.

LED INDICATORS. LED 1 is the indicator for the +15V DC regulated power supply which is fused by

F5 on the Control Fuse Assembly board CP38-17. LED 2 is the indicator for the -1 5V DC regulated power supply which is fused by F6

on CP38-17. LED 3 is the indicator for the +5V DC regulated power supply which is fused by F7

on CP38-17. LED 4 is referred to as the 'Beacon'. It flashes to indicate that the CP38-IO

microprocessor circuit is functioning correctly. If LED 4 is either on or off continuously, or flashing erratically, a fault involving the microprocessor is indicated.

LED 5 is lit to indicate continuity of the remote pendant 'Current' circuit. LED 6 is lit to indicate continuity of the remote pendant 'Arc Length' circuit.

TEST POINTS. TP A is circuit board common and reference for the test points below. It is tied to

machine Earth via 47kQ. TP B provides access to the 'Descriptive Signal'. Observed with an oscilloscope,

the signal defines the welding pulse width and pulse frequency. Refer to Figure 8 opposite.

TP C provides access to the 'Current signal'. Observed with an oscilloscope, the waveform represents actual arc current scaled at 1V = 50 Amps arc. This test point is also used during adjustment of the shunt amplifier null as described below.

TP D provides access to the 'Voltage signal'. Observed with an oscilloscope, the waveform represents actual arc voltage scaled at 1V = 5 Volts arc.

TP E is a DC voltage in the range 0 - IOV representing the setting of the remote control pendant 'Arc Length' potentiometer.

TP F is a DC voltage in the range 0 - 1OV representing the setting of the remote control pendant 'Current' potentiometer.


EPROM The operating code for the microprocessor is stored in a memory device called an

Eprom (Erasable Programmable Read Only Memory). The Eprom for the CP38-10 board is fitted to a socket which allows the device to be changed. This may be required when fitting a Robot isolation board, or to implement new machine features which may become available. An Eprom intended for use in a CP38-10 board will always have a code number beginning with the numbers '380'. When fitting a new Eprom:

Touch 'Earthed' metal before handling the device and avoid touching the pins, as an Eprom can be destroyed by static electricity. The Eprom should be supplied in static-proof packaging.

original device.

w Carefully insert the replacement Eprom into the socket with fhe nofched end of the device pointed towards the component U7. Ensure that all of the device pins are engaged in the socket.

Lift up the orange coloured tags on both ends of the socket, then remove the

w Press down both orange tags which will 'click' into position, locking the Eprom into the socket.

SHUNT AMPLIFIER NULL ADJUSTMENT. This procedure must be carried out any time the CP38-10 board is replaced. The Shunt Amplifier circuit of the CP38-IO board incorporates a nulling

potentiometer RV1 which is to be adjusted so that the output of the amplifier is zero when no welding output current is flowing. As a small bias current is passed through the current shunt by the CP38-10 circuit, the null point must be sef wifh fhe shunf and associated wiring loom connected.

Connect a digital multimeter, set to its lowest DC voltage range, between TP A (circuit common), and TP C (current signal). With the machine energised but not welding, adjust potentiometer RV1 to achieve a near 0 mV meter reading. A reading between k 10 mV is acceptable.

1

l l l

I I

I I

1 I

I I

ARC CURRENT

l"u-L DESCRIPTIVE SIGNAL

FIGURE 8. DESCRIPTIVE AND CURRENT SIGNAL.


8V IN

IN

SPEED SIG -0-12.15V DC

ALL 12mA=OK

EXTERNAL FAULT INPUT (BYPASSED)

12V AC VIA THERMOSTATS

TO SOLID STATE RELAY

FIGURE 9. WELDING CPU BOARD CP38-IO.


DISPLAY CPU ASSEMBLY CP38-11. This board is a microprocessor based circuit which is dedicated to the CDT 450

user interface. It performs the following functions:

Reads the operator keypad;

Displays messages on the LCD display screen;

Sends serial transmissions to the Welding CPU Board defining the selected Weld Schedule and options.

M Stores all settings and downloaded Weld Schedules.

~

Stores the library of Weld Schedules. LED INDICATORS.

the Control Fuse Assembly CP38-17. TEST POINTS.

L1 is the indicator for the +5V DC regulated power supply which is fused by F7 on

TPO is circuit board common and reference for the test points below. TP1 provides access to the +5V DC regulated supply as indicated by L1 above. TP2 provides access to the -1 5V DC regulated supply, which is fused by F6 on the

TP3 provides access to the +15V DC regulated supply, which is fused by F5 on the Control Fuse Assembly CP38-17.

Control Fuse Assembly CP38-17. ADJUSTMENTS.

The Display Contrast adjustment should be set to provide optimum contrast when the display is viewed from the operating position. The contrast should not require routine adjustment, as variation of contrast due to temperature change is electronically compensated for. EPROM

The operating code for the microprocessor and the library of weld schedules is stored in a memory device called an Eprom (Erasable Programmable Read Only Memory). The Eprom for the CP38-l l board is fitted to a socket which allows the device to be changed. This may be required to implement any new machine features or weld schedules which become available. An Eprom intended for use in a CP38-1 l board will always have a code number beginning with the numbers '381'. When fitting a new Eprom:

Touch 'Earthed' metal before handling the device and avoid touching the pins as an Eprom can be destroyed by static electricity. The Eprom should be supplied in static-proof packaging.

Lift up the orange coloured tags on both ends of the socket, then remove the original device.

Carefully insert the replacement Eprom into the socket with the notched end of the device pointed towards the word 'DISPLAY'. Ensure that all of the device pins are engaged in the socket.

Press down both orange tags which will 'click' into position, locking the Eprom into the socket.

SERIAL CONNECTOR.

as the connection point for a separate programming device. Connector P2, labelled 'SERIAL' is not used in a standard CDT 450. It is provided


m n z m CIQ A 0 wm 2, OQ- +-U

x A z

0 . +g CL: W v)

r c

>k

cna n

6- AI- Q0

I 7

El

1 5 { z U

0 F{$ '2; - cl

n l

[ v/ ; ?

a U

/ @ lCVo

Z Y - B 4 s

C V 5 r 5 %

& =

m

5 3 W O

a L-

U

7 0 U

Ho0 g x :r g o o a o o

0 0

I_* +o m* I -S Q - v

n a +L O t l

Y

FIGURE I O . DISPLAY CPU BOARD CP38-11.

SYNCHRO-PULSE CDT 450 MANUAL Paae 33 "

~ ~~ ~ _ _ _ _ _ _

TRANSISTOR DRIVER BOARD CP38-12. This board, in conjunction with some off-board components, drives the output

transistors of the Transistor Switch Assembly in response to drive signals from the Welding CPU board CP38-IO. It is mounted on the right side (facing the front of the CDT) of the Transistor Switch Assembly CP38-24.

A.C voltage supplies to the board are:

Three phase, 1 0V AC from auxiliary windings of the welding transformer. This is rectified, fused and filtered off-board to form a high-current +l OV DC supply for base current to the output transistors via the driver transistors. The three phase is also rectified on-board to form a +l 0 V DC control voltage supply.

board to form a -10 V DC supply for base discharge of the main transistors via the driver transistors.

w 8V AC, via fuse F1 of the Control Fuse Assembly CP38-17. This is rectified on-

The board includes means for detecting four separate fault conditions:

Failure of an on-board power supply;

w Mains Supply phase failure;

Mains Supply high;

Mains Supply low.

If a fault is detected, on-board hardware prevents further operation of the transistors, and signals the fault to the Welding CPU Board CP38-IO. The four fault status lines to the Welding CPU Board, labelled in circuit diagrams 'ERR TS', 'ERR VU, 'ERR VH', 'ERR PF', are failsafe current loops, ie current flow = OK.

BASE NPN EMITTER NPN

BASE PNP

+1OV DC 4 -1OV DC

3 d 1OV AC

{=l

- o~ oo-n aO_

-8 I=- 0

1_1 Os O , a - /_1 U eIlcr>,aa El 0 M 00 1 -BolpofO 1 ioOOU1): L-l TP1e "-4Og - CJ p E ? q O @

L-l "- I-1

0 COM WIA PART CPUI-l2 0

MAOE H AUSTRACIA BY WELDING INDUSTRIES OF AUSTRALIA

"

"

"

"

"

"

"

"

"

-

8 V AC

TS COM ERR TS

TS DRV ERR COM

ERR PF ERR VH ERR VL

FIGURE 11. TRANSISTOR DRIVER BOARD CP38-12.


BACKGROUND DRIVER BOARD CP38-13. This board drives the background Transistors in response to drive signals from the

Welding CPU Board CP38-IO. It is mounted on the left side of the Transistor Switch Assembiy CP38-21.

AC voltage supply to the board is 15V AC, rectified and filtered on-board to form a nominal +20V DC unregulated control voltage. If this power supply fails, on-board hardware inhibits further operation of the background transistors, and signals the fault to the Welding CPU Board CP38-IO. The fault status line, labelled ERR BG in circuits, is a failsafe current loop, ie current flow = OK.

Transistors H I and H2 are directly connected to the Background Transistors and are likely to be damaged should these fail. If this occurs, replace the entire Background Switch assembly CP38-32.

10 0 c90 0 0 I

-U TU ztl 0 U U -E5 " " BAMGRWNO FET ORNER ASSEMBLY El D - 5 a " H E ~DE~-H-

-cT=+

o CP38-13 [ 1 [ 1 1 1 W.lA. PART No. 0 1

$/G COMMON

B/G DRIVER 15V AC F2

ERR B/G ' ERR COMMON I

FIGURE 12. BACKGROUND DRIVER BOARD CP38-13.


WIRE/GAS CONTROL BOARD CP38-16. This board provides the following circuit functions:

Speed control of the wirefeed motor;

Dynamic braking of the wirefeed motor at end of weld;

Switching of the gas solenoid valve;

Gun switch (relay) buffering. Connections to the board and adjustment points are detailed in the drawing below.

MOTOR SPEED CALIBRATION For correct operation of the CDT 450, it is important that the wirefeed motor speed

be correctly calibrated. This must be carried out any time the CP38-16 board or the wirefeed motor is replaced. To check and adjust the wirefeed motor speed:

Disengage the wirefeed drive mechanism;

At the keypad select OPTION > SERVICE > WIREFEED MAX;

Using an accurate tachometer, monitor the speed of the wirefeed drive rolls. Adjust RV1 as required to obtain 126 rpm.

Press any key or the gun switch to exit this mode.

30V AC

""

(DOTTED LINE)

! k i % i F { : : - : ; : e l 1 BASE [j p COMMON WIF STATUS GAS ON WIRE ON

COMMON GUN SWITCH COMMON (+l MOTOR

i 12V AC VIA THERMOSTATS

GUN SWITCH

GAS VALVE SPEED SIGNAL-0-12.6V DC

{ \ (-) PUSH-PULL

FIGURE 13. WIRE/GAS BOARD CP38-16.

~


CONTROL FUSE ASSEMBLY CP38-17.

PROVISION FOR REVERSING RELAY

FROM CONTROL TRANSFORMER I 8V AC

IN AC

IN AC

IN AC

12V AC TO THERMOSTATS

15V AC

8V AC

DRIVER CP38-13 8V AC TO TRANSISTOR

DRIVER CP38-12 I I

€!.!sua - 1

CPU +N 7 CPU -IN 6 CPU +15V 5 SHUNT AMP. + / - W 4 GUN CIRCUIT 3 BACKGROUND CIRCUIT 2 TRANSISTOR CIRCUIT

I

FIGURE 14. CONTROL FUSE ASSEMBLY CP38-17. l

I

SYNCHRO-PULSE CDT 450 MANUAL Page 39

13. PARTS LISTS.

SYNCHRQ-PULSE CDT 450 POWER SOURCE CP38-3

ITEM # PART # DESCRIPTION 1 .......................... CP38-10 .............................. Welding CPU Board 2 .......................... CP38-16 .............................. WireiGas Board 3 .......................... CP38-17 .............................. Control Fuse Assembly 4 .......................... CP38-104 ............................ Arc Voltage Filter Assembly 5 .......................... CP38-21 .............................. Main Switch Assembly (See Following List) 6 .......................... CP38-22 .............................. Transformer Assembly 7 .......................... CP38-50 .............................. Keypad/Display Assembl (See Following List) 8 .......................... CP38-51 .............................. Rectifier Assembly (See F ollowing List) 9 .......................... CP38-54 background Inductance 10 ......................... CP38-80 .............................. Pulse Inductance 1 1 ......................... CP38-41 .............................. Base Assembly 12 ......................... CP38-42 .............................. Front Panel 13 ......................... CP38-43 .............................. Door 14 ......................... CP38-77 .............................. Front Grille 15 ......................... CP38-46 .............................. Back Panel 16 ......................... CP38-78 .............................. Side Panel R.H. 17 ......................... CP38-79 .............................. Side Panel L.H. 18 ......................... CP38-49 .............................. Top Panel 19 ......................... CP38-58 .............................. Large Fan Guard 20 ......................... CP38-59 .............................. Small Fan Guard 21 ......................... CP38-35 .............................. Capacitor Bank Assembly 22 ......................... CP38-36 .............................. Earth Shield Plate 23 ......................... CP38-37 .............................. Divider Panel 26.. ....................... CP38-60 ............................. .Busbar Positive 27 ......................... CP38-61 .............................. Busbar Link Positive 28 ......................... CP38-62 .............................. Busbar Ne ative 29 ......................... CP38-63 .............................. Busbar Lin i? Negative 30 ......................... CP38-64 .............................. Busbar Background

30.1 ................... CP38-64/1 .......................... .Busbar Horizontal 30.2 ................... CP38-64/2 ........................... Busbar Vertical

31 ......................... CP38-81 .............................. Busbar Ta - Inductance 32 ......................... CP38-82 ............................. .Busbar In d" uctance 33 ......................... CP38-83 .............................. Busbar Shunt 34 ......................... CP38-65 .............................. Resistor Assembly 35 ......................... CP38-0/5 ............................. Control Transformer 36 ......................... CP38-016 ............................. Contactor Transformer 37 ......................... CP38-67 .............................. Spacer 38.. ....................... CP38-68 .............................. Llfting Rod 39 ......................... M08029F ............................. Eyenut 1/2" 44 ......................... AM16-5 ................................ Output Socket Assembly 45 ......................... AMl6-0 ................................ Output Socket Assembly

Including

46. ........................ CP34-0/28 ........................... Gas Valve Assembly Including

46.1 ................... CP101-0/18 ......................... Gas Valve 46.3 ................... W17-14/1 ............................. Gas Valve Connection 46.4 ................... TC262 ................................. Gas Outlet 46.5 ................... TC262N ............................... Nut

47. ........................ CP34-2/39 ........................... Resistor 51 ......................... CP102-0/18 ........................ .Circuit Board Support 52 ......................... W1 -23 ................................. Fuse Holder 53 ......................... F3AGlOA ............................ Fuse 10A 3AG 54 ......................... F3AGlSA ........................... Fuse 1.5A 3AG 60 ......................... CP38-56 .............................. Wiring Loom

Including 60.1 ................... CP38-0/8 ............................. Cannon Socket AXR-3-21 60.2 ................... CP34-0/14 ........................... Cannon Socket AP-8-21

61 ......................... CP34-OU8 ........................... Shunt 400A / 50mV / 0.5% Tol. 62 ......................... CP38-3/1 ............................. Contactor 240 Volt Coil 65 ......................... CP34-44/1 ........................... Filter Capacitor 68 ......................... CP22-3/13 ........................... Insulator 69 ......................... CP38-28 .............................. Nichrome Resistor 70 ......................... CP38-28/1 ........................... lnsulstruc Insulator 72 ......................... CP38-0/12 ........................... Contactor 32 Volt Coil 73 ......................... CP38-0/13 ......................... ..Solid State Relay 74 ......................... CP38-103 ............................ Fuse Bracket 75 ......................... CP33-0/12 ........................... Fuse Holder (HRC T pe) 76 ......................... S56-0/11 .............................. Fuse Link (10 Amp ype "T" 131 ................................................................... %"Whitworth x %' +y aptlte Screw 132 .................................................................. .M5 x 12mm Taptite Screw


AIR -

U LEFT VIEW (BACKGROUND ASSEMBLY)

n

USE DOW-CORNING HEATSINK COMPOUND

No.340 BETWEEN ALL SURFACES WHERE

THERMAL CONTACT IS REQUIRED.

FiGURE 17. MAIN SWiTCH ASSEMBLY CP38-21.

l l


MAIN SWITCH ASSEMBLY CP38-21

ITEM # PART # DESCRIPTION

1 .......................... CP38-21/1 ........................... Aluminium Heatsink 2 .......................... CP38-21/18 ......................... Fan Assembly 3 .......................... CP38-21/6 ........................... Sealing Pfate 4 .......................... CP38-21/7 ........................... Fan Plate 5 .......................... CP38-21/8 ........................... Bottom cover 6 .......................... CP38-21/9 ........................... Busbar (Emitter) 7 .......................... CP38-21/10 ......................... Busbar (Bo) 8 .......................... CP38-21/11 ......................... Busbar (B) 9 .......................... CP38-21/12 ......................... Connecting Link 10 ......................... CP38-21/4 ........................... Side Insulation 1 1 ......................... CP38-21/16 ......................... Transistor 12 ......................... CP38-21 /l 4 ......................... Fast Diode 12.1 ...................... CP38-21/15 ......................... Diode Clamp 13 ......................... CP3-918 ............................... Thermostat 95°C 14 ......................... CP38-31 .............................. Transistor Driver Assembly 15 ......................... CP38-32 .............................. Background Assembly 16 ......................... CP38-21/13 ......................... Insulating Spacer (Top) 17 ......................... CP38-21/1 7 ......................... Insulating Spacer (Bottom) 18 ......................... CP38-21/19 ......................... Bolt Insulator


KEYPAD ASSEMBLY CP38-50.


l ........................... CP38-45 .............................. Sheetmetal Panel 2 .......................... .CP38-50/1 ........................... Printed Membrane 3 ........................... CP38-50 ........................... Clear Window 4 .......................... .CP38-50/7 ........................... LCD Display Assembly 5 ........................... CP38-18 .............................. Press Button PCB Assembly 6 ........................... CP38-11 .............................. Display CPU Assembly 7 ........................... CP38-50/4 ........................... Spacer 1 1 mm 8 ........................... CP38-50/5 ........................... Spacer 6.4rnm 9 ........................... CP38-50/6 ........................... Nut 8mm 10 ........................ .CP38-50/8 ........................... Rocker Switch

U

t I

FIGURE 18. KEYPAD ASSEMBLY CP38-50.


RECTIFIER ASSEMBLY CP38-51.


1 .......................... CP38-51/1 ........................... Heatsink 2 .......................... CP38-5112 ........................... Insulating support 3 .......................... CP15-13/2 ........................... Diode Cathode Stud 4 .......................... CP15-13/3 ........................... Diode Anode Stud 5 .......................... CP3-9/8 ............................... Thermostat 95°C 6 .......................... MC36-6518 ........................... Capacitor 7 .......................... CP38-53 .............................. Fan Mounting Bracket 8 .......................... CP38-5115 ........................... Fan Motor 9 .......................... CP38-51/6 ........................... Fan Blade 10 ......................... CP38-5113 ........................... Terminal stud 11 ......................... MC1 1-322 ........................... Nylon Insulating Bush 12 ......................... W1 1-1 3 ............................... Insulator 13 ......................... CP38-51/4 ........................... Support Spacer

NOTE 1. USE DOW-CORNING HEATSINK COMPOUND N0.340 BETWEEN ALL SURFACES WHERE THERMAL CONTACT IS REQUIRED.

2. TORQUE DIODE NUTS TO 30Nm. 3. WHEN FITTING FAN BLADE. ENSURE

BLADES ARE WELL CLEAR OF DIODES.

FIT WHER

FIGURE 19. RECTIFIER ASSEMBLY CP38-51.


W35-0 REMOTE WIREFEEDER ASSEMBLY.


1 ........................... W351 l ............................... Case Assembly 2 ........................... AM177 ................................ Spool Holder Assembly 3 ........................... W21-11/9 ............................ Dust Flap Mounting Rod 4 ........................... AM1 38-2 ............................. Plastic Dust Flap 5 ........................... W24-2 ................................. Wirefeed Motor and Drive Assembly

Including 5.1 ..................... W17-01/6 ............................ Wirefeed Motor 5.2 ..................... W2-44 ................................. Two Roll Drive Assembly 5.3 ..................... W2-20 ................................. Fiat Drive Roller 5.4 ..................... W2-22 ................................. Grooved Drive Roller 5.5 ..................... W2-44/12-1 ......................... Input Wire Guide

6 ........................... K34 ..................................... Cannon Socket 9 ........................... TC262 ................................. Gas Inlet 10 ......................... TC262N ............................... Nut 19 ......................... W24-0/6 .............................. EZ Quick Connect Assembly 20 ......................... W2-44/20 ............................ Small I.D. Guide Tube 21 ......................... W2-44/19 ............................ Adaptor

~

I l

FIGURE 20. WIREFEEDER ASSEMBLY W35-0.

-

~


W2-44 TWO ROLL DRIVE ASSEMBLY

ITEM # PART ## DESCRIPTION

1 .......................... W2-44/1 .............................. Die Cast Body 2 .......................... W2-44/2 .............................. Top Roller Housing 3 .......................... W2-44/25.. ........................... Shaft 4 .......................... SSGM510U ......................... M5 Skt. Grub Screw x 10 long 5 .......................... W2-17 ................................. Washer

7 .......................... SSKM51OU .......................... M5 Skt. Hd. Screw x 10 long 8 .......................... W2-44/35 ............................. M8 Shoulder Skt. Screw x 20 long

10 ......................... W2-44/6 ..............................Tension Arm l 1 ......................... W2-44/13.. ........................... Spring

13 ......................... W2-44/8 .............................. Top Roll Shaft 14 ......................... W2-44/031 ........................... Bearing(lnner)608ZZ 15 ......................... W2-44/030 ........................... B e a r 17 ......................... W2-15 ................................. Driven Gear Wheel 19 ......................... SO305029 ............................ 8-32 UNC Skt. Hd. Screw x %"long 20 ......................... W2-l6 .....................I...........Driving Gear Wheel 21 ......................... SSNM36Z ............................ M3 Pan Hd. Screw x 6 long 22 ......................... SSKM515U .......................... M5 Skt. Hd. Screw x 15 long 23 ......................... SSKM612U .......................... M6 Skt. Hd. Screw x 12 long 24 ......................... SSSM612U .......................... M6 Csk. Skt. Hd. Screw x 12 long

28 ......................... W2-44/22 ............................. M24 x 1P Brass Locknut

31 ......................... SSKM815U .......................... M8 Skt. Hd. Screw x l 5 long

33 ......................... W2-4415 .............................. Insulating Ring 34 ......................... W2-44/21 ............................. Flat Washer

6 .......................... WSE5.Z ................................ 5 Dia Shakeproof Washer

9 .......................... JW418 ................................. 8 Dia Belleville Washer

12.. ....................... W2-44/7 .............................. Nut

16 ......................... W2-44/016 ........................... M6 Hex Dome Nut

27. ........................ W2-44/26 ............................. Adaptor Bush

29 ......................... SSKM825U .......................... M8 Skt. Hd. Screw x 25 long 30 ......................... WSS8Z ................................ 8 Dia Spring Washer

32 ......................... WSP8Z ................................ 8 Dia Plain Washer

FIGURE 21. TWO ROLL DRIVE ASSEMBLY W2-44.

-~


DRIVE ROLL AND WIRE GUIDE TABLE.

0 0 CIn C

- WIRE DIA

mm B c PLAIN 'V' ROLLER 1 BRASS FLAT ROLLER

1

w2-21 1 w2-20 0.8

0.9 w2-20 W2-22

W2-44/12-1

1.2

PLAIN 'V' ROLLER PLAIN 'V' ROLLER

1.6 w2-22 W2-22 I W2-44/12-2

KNURLED 'V' ROLLER KNURLED 'V' ROLLER

l .2 W2-51 w2-51 W2-44/12-1

1.6 w2-24 w2-24 1 W2-44112-2

2.0 2 -4 w2-25 : w2-25

W2-26 W2-44/12-3

3.2 W2-26

w2-27 _____I w2-27

W2-28 W2-44/12-4

4.0 5.0 W2-28

60"'V'ROLLER POUBLE GROOVE I NYLON FLAT ROLLER

l .2 w2-20 w2-54 I W2-44/12-1N

1.6 w2-20 w2-54 I W2-44/12-2N

PLAIN 'V' ROLLER

W2-22

PLAIN 'V' ROLLER

1.6 W2-22 W2-44/12-3N w2-23 W2-44/12-2N

2.4 w2-23

FLAT ROLLER OPEN 'U' ROLLER

0.9 w2-48 W2-49

w2-49

W2-44/12-1N 1.2

1.2 w2-50 t"-- W2-44/12-1N

W2-44/12-2N 1.6

FIGURE 22. DRIVE ROLL AND WIRE GUIDE TABLE.


BE2-4410A GUN ASSEMBLY

ITEM #..PART # ...... DESCRIPTION 3 ....... BE4435 ...... Head

Includes 3A..BE7127 ...... 0 Ring 3B ..BE7560 ...... Retaining Ring 3C..BE1510 ...... Snap Ring

4 ....... BE4423 ...... Cap 5 ....... BE4780 ...... Insulator Hex. Nut 6 ....... BE4790 ...... Body Tube 7 ....... BE441 38 .... End Fitting 8 ....... BE4416 ...... Cone Nut 9 ....... BE4408 ...... Handle Kit 10 ...... BE4434 ...... Hang Up Hook 11 ...... BE4426 ...... Screw Kit 12 ...... BE4422 ...... Trigger Assembly 15 ...... BE1880074 Rear Connection Case 16 __.___ BE252009 _. Rear Cable Support 18 ...... BE4451 ...... 10' Cable Assembly 19 ...... BE1 199 ...... Quick Connect Fitting Kit

Includes A .... BE4924 ...... Lead wires B .... BE4925 ...... Locking Sleeve C....BE4292 ...... Power Pin D .... BE4929 ...... 0 Rings E....BE4913 ...... Nut F .... BE4909 ...... Star Washer G .... BE4901 ...... Quick Connect body H....BE4911 ...... Snap ring (Large) I ..... BE491 6 ...... Wave Spring

ITEM # . PART # ....... DESCRIPTION J .... BE4912 ....... Snap Ring (Small) K1 . BE4907 ....... 0 Ring K2 . BE4906 ....... Gas Pin

Liners BE441 15 .............. 0.9 - 1.2mm BE4421 5 .............. 1.2 - 1.6mm BE44315 .............. 2.0mm BE431 15X ............ 0.9 - 1.2mm Nylon BE44215X ............ 1.2 - 1.6mm Nylon

Nozzles BE4491 ................ Brass 19mm BE4492 ................ Tapered 13mm BE4591 ................ Copper 19mm

Contact Tips BE7497 ................ 0.6mm BE7488 ................ 0.8mm BE7489 ................ 0.9mm BE7496 ................ 1 .Omm BE7490 ................ 1.2mm BE7498 ................ 1.3mm BE7491 ................ 1.6mm BE7492 ................ 2.0mm BE7493 ................ 2.4mm BE7494 ................ 2.8mm

When fitting a liner, the new part must be cut to the correct length. After passing the liner into the gun cable, attach the quick connect fitting to the wirefeeder, then at the gun end compress the liner within the cable. Cut the liner one tip length past the end of the body tube (6), then remove any burrs with a file.

NOZZLE LINER

r 1 1 1 1 I 1 I """"""~"

FIGURE 23. GUN CABLE ASSEMBLY BE2-441OA

~ Page 48 SYNCHRO-PULSE CDT 450 MANUAL

~

l AM223 ACCESSORY LEAD KIT.


1 ........................... AMI 5 .................................. Welding Current Plug Assembly 2 ................................................................... . G' Type Work Clamp 3 .......................... .CABW70 ......................... ____Welding Cable 70mm2 4 ........................... H1431 ................................. Crimp Lug 5 ........................... AM145-3/1 .......................... Cannon Cord Plug, 8 pin Male 6 ........................... CAB8C32 ............................ 8 Core Control Cable 7 ........................... AM145-3/2 .......................... Cannon Cord Plug, 8 pin Female 8 ........................... HOSSR ............................... Gas Hose 5mm ID 9 ........................... TC362 ................................. Gas Hose Tail l 0 ......................... TC362N ............................... Hose Tail Nut

12 ......................... OCL13 ................................ '0' Clip 11 ......................... OR1 0.6 .............................. Rubber '0' Ring -

l 1

I 0

Y

WORK -<? LEA

r 2 L < - g q p WELDING LE D

""j WIRE FEEDER CONTROL CABLE

7

F y i": +c)+"+ G A S H O S E gzu

GAS HOSE (FROM CYLINDER)

FIGURE 24. AM223 ACCESSORY LEAD KIT


14 . PULSED GMAW WELD SCHEDULE LIST #38146/60

CARBON & ALLOY STEELS SCHED DIAM MATERIAL GAS COMPOSITION GAS NAMES #l55 ........ 0.6mm ....... Carbon Steel ............. Argon +IO% C02 ............................. M5, CGIO #l56 ........ 0.8mm ....... Carbon Steel ............. Argon +IO% C02 ............................. M5, CGIO #286 ........ 1 . Omm ....... Carbon Steel ............. Argon +IO% C02 ............................. M5, CGIO #361 ........ 1.2mm ....... Carbon Steel ............. Argon +IO% C02 ............................. M5, CGIO #l47 ........ 1.6mm ....... Carbon Steel ............. Argon +IO% C02 ............................. M5, CGIO M 4 0 ........ 0.9mm ....... Carbon Steel

SOFTARC USE CC OUTPUT ..... Argon +18% C02 ............................. M I . CG18, AR51

# l58 ........ l.Omm ....... Carbon Steel ............. Argon +IS% C02 ............................. MI , CG18, AR51 # l57 ........ 0.9mm ....... Carbon Steel ............. Argon +18% C02 ............................. MI , CG18, AR51

# l59 ........ 1.2mm ....... Carbon Steel ............. Argon +18% C02 ............................. MI , CG18, AR51 #234 ........ 1.6mm ....... Carbon Steel ............. Argon +18% C02 ............................. MI , CG18, AR51 #273 ........ 1.6mm ....... Carbon Steel ............. Argon +16% C02+2.5% 0 2 .............. AR51,CG2, M I #244 ........ 1.2mm ....... Carbon Steel ............. Argon +25% C02 ............................. M3, AR52 #415 ........ 1.2mm ....... Carbon Steel ............. Argon +26% He +8%C02 +0.5%02. ARGOSHIELD 100 #377 ........ 1 . Omm ....... Carbon Steel ............. Argon +5% C02 +2% 0 2 ................. CG5.2, AR50 #295 ........ 1.2mm ....... Carbon Steel ............. Argon +5% C02 +2% 0 2 ................. CG5.2, AR50 #447 ........ 0.9mm ....... Carbon Steel

SOFTARC USE CC OUTPUT ..... Argon +7% C02 + IS% 02 ............... AR54, AR50 #262 ........ 1.2mm ....... Carbon Steel ............. Argon +7% C 0 2 + l 5% 0 2 ............... AR54, AR50 #310 ........ 0.9mm ....... Carbon Steel ............. Argon + I S % 0 2 ............................... ARGO, S1 #l 52 ........ 1.2mm ....... Carbon Steel ............. Argon +5% 0 2 .................................. CG05, AR40, AR'L' #250 ........ 0.9mm ....... Carbon Steel ............. Argon +7% 0 2 .................................. M4, CG07 #251 ........ 1.2mm ....... Carbon Steel ............. Argon +7% 0 2 .................................. M4, CG07 #327 ........ 1.6mm ....... Low Alloy Steel ......... Argon +lo% C02 ............................. M5, CGIO #326 ........ 1.6mm ....... Low Alloy Steel ......... Argon +5% C02 ............................... CG05, AR40, AR'L' #l44 ........ 1.2mm ....... Linde 95 .................... Argon +5% C02 ............................... CG05, AR40, AR'L' # l45 ........ l . 6mm ....... Linde 95 .................... Argon +5% C02 ............................... CG05, AR40, AR'L' #320 ........ 0.9mm ....... Linde 120 .................. Argon +5% C02 ............................... CG05, AR40, AR'L' #321 ........ 1.2mm ....... Linde 120 .................. Argon +5% C02 ............................... CG05, AR40, AR'L' #270 ........ 0.9mm ....... Linde 120 .................. Argon +2% 0 2 .................................. AR60, S1 #271 ........ 1.2mm ....... Linde 120 .................. Argon +2% 0 2 .................................. AR60, S1 #l43 ........ 1.6mm ....... Linde 140 .................. Argon +5% 0 2 .................................. CG05, AR40, AR'L'

I STAINLESS STEELS SCHED DIAM MATERIAL GAS COMPOSITION GAS MIXES #399 ........ 0.9mm ....... Stainless 307 Si ........ Argon +l . 5% 0 2 ............................... AR60, S1 #400 ........ 1.2mm ....... Stainless 307 Si ........ Argon +l S% 0 2 ............................... AR60, S1 #309 ........ 0.9mm ....... Stainless 308L .......... Argon + l . 5% 0 2 ............................... AR60, S1 #l80 ........ 0.9mm ....... Stainless 308LSi ....... Argon + IS% 0 2 ............................... AR60, S1 #218 ........ 1.2mm ....... Stainless 308LSi ....... Argon + l . 5% 0 2 ............................... AR60, S1 #393 ........ 0.9mm ....... Stainless 308LSi ....... Argon +30% He +3% C02+1% H2 ... MlGshield 54 #394 ........ 1.2mm ....... Stainless 308LSi ....... Argon +30% He +3% C02+1% H2 ... MlGshield 54 #220 ........ 1.6mm ....... Stainless 308LSi ....... Argon +30% He +5% C02 ................ AR61, S4 #314 ........ 0.8mm ....... Stainless 309 ............ Argon +30% He +5% C02 ................ AR61, S4 # l 89 ........ 0.9mm ....... Stainless 309L .......... Argon +30% He +5% C02 ................ AR61, S4 # l 90 ........ 1.2mm ....... Stainless 309L .......... Argon +30% He +5% C02 ................ AR61, S4 #290 ........ 0.9mm ....... Stainless 309L .......... Argon +50% He ................................ BS2, HEL50 #291 ........ 1.2mm ....... Stainless 309L .......... Argon +50% He ................................ BS2, HEL50 #332 ........ 0.9mm ....... Stainless 309LSi ....... Argon +l . 5% 0 2 ............................... AR60, S1 #297 ........ 0.9mm ....... Stainless 309LSi ....... Argon +5% 0 2 .................................. CG05, AR40, AR'L'

~ #298 ........ 1.2mm ....... Stainless 309LSi ....... Argon +5% 0 2 .................................. CG05, AR40, AR'L' #340 ........ 1.2mm ....... Stainless 3091si ~

l BHP 3CR12 plate ..... Argon + IS% 0 2 ............................... AR60, S1 #389 ........ 0.9mm ....... Stainless 309LSi ....... Argon +35% He +1%02 ................... 3CR12/Argo 69 #390 ........ 1.2mm ....... Stainless 309LSi ....... Argon +35% He +1%02 ................... 3CR12/Argo 69 #267 ........ l.Omm ....... Avesta P5 ................. Argon +30% He +5% C02 ................ AR61, S4


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~

i

#237 ......... 0.9mm ....... Stainless 310 ............. Argon +l 5% 0 2 ............................... AR60, S i #238 ......... 1.2mm ....... Stainless 310 ............. Argon +l S% 0 2 ............................... AR60, 51 #l88 ......... 0.9mm ....... Stainless 312 ............. Argon +30% He +5% C02 ................ AR61, 54 #241 ......... 1.2mm ....... Stainless 312 ............. Argon + l . 5% 0 2 ............................... AR60, 51 .

#l98 ......... 1 . Omm ....... Stainless 316L ........... Argon +35% He +3% C02 ................ STAINSHIELD HEAVY #l99 ......... 1.2mm ....... Stainless 316L ........... Argon +35% He +3% C02 ................ STAINSHIELD HEAVY #200 ......... 1.6mm ....... Stainless 316L ........... Argon +35% He +3% C02 ................ STAINSHIELD HEAVY #l82 ......... 0.8mm ....... Stainless 316LSi ........ Argon + l . 5% 0 2 ............................... AR60, 51 #380 ......... 0.9mm ....... Stainless 316LSi ........ Argon +35% He +3% C02 ................ STAINSHIELD HEAVY #438 ......... 0.9mm ....... Stainless 316LSi ........ Argon +30% He +5% C02 ................ AR61, 54 #449 ......... 0.9mm ....... Stainless 316LSi

#l97 ......... 0.8mm ....... Stainless 316L ........... Argon +35% He +3% C02 ................ STAINSHIELD HEAVY

SOFTARC USE CC OUTPUT .... Argon +20% He +2% C02 ................ Cronigon He20 #l91 ......... 0.9mm ....... Stainless 316LSi ........ Argon +30% He +5% C02 ................ AR61, 54 #l92 ......... 1 . Omm ....... Stainless 316LSi ........ Argon +30% He +5% C02 ................ AR61, 54 #l79 ......... 0.9mm ....... Stainless 316LSi

BHP 3CR12 plate ..... Argon +30% He +5% C02 ................ AR61, 54 #395 ......... 0.9mm ....... Stainless 316LSi ........ Argon +30% He +3%C02+1%H2 ...... MlGshield 54 #l83 ......... 0.9mm ....... Stainless 316LSi ........ Argon + l . 5% 0 2 ............................... AR60, 51 #l93 ......... 1.2mm ....... Stainless 316LSi ........ Argon +30% He +5% C02 ................ AR61, 54 #381 ......... 1.2mm ....... Stainless 316LSi ........ Argon +35% He +3% C02 ................ STAINSHIELD HEAVY # l 84 ......... 1.2mm ....... Stainless 316LSi ........ Argon + l 5% 0 2 ............................... AR60, S I #396 ......... 1.2mm ....... Stainless 316LSi ........ Argon +30% He +3%C02+1 %H2 ...... MlGshield 54 #293 ......... 0.9mm ....... Stainless 316LHiSi ..... Argon +2% 0 2 .................................. AR60, 51 #239 ......... 0.9mm ....... Stainless 347 ............. Argon +1.5% 0 2 ............................... AR60, S I #282 ......... 0.9mm ....... Stainless 347 ............. Argon +30% He +5% C02 ................ AR61, 54 #283 ......... 1.2mm ....... Stainless 347 ............. Argon +30% He +5% C02 ................ AR61, 54 #l24 ......... 1.2mm ....... Cronifer 1925hMo ...... Argon - high purity ............................. Ar-HP #240 ......... 1.2mm ....... Stainless 1707 ........... Argon + l . 5% 0 2 ............................... AR60, 51

SANDVIK 22.8.3L ..... Argon +30% He +5% C02 ................ AR61, 54




#305 ......... 0.8mm ....... Stainless SAF 2205

#l77 ......... 0.9mm ....... Stainless SAF 2205

#334 ......... 1 . Omm ....... Stainless SAF 2205

M 3 4 ......... 1 . 2mm ....... Stainless SAF 2205

# l 78 ......... 1.2mm ....... Stainless SAF 2205

#316 ......... 1.2mm ....... Stainless SAF 2507

#317 ......... 1.2mrn ....... Stainless SAF 2507

#441 ......... 1.2mm ....... Stainless SAF 2209 ... STAINSHIELD 69 M 4 2 ......... 0.9mm ....... Stainless SAF 2209 ... STAINSHIELD 69


SANDVIK 25.10.4L ... Argon +1.5% 0 2 ............................... AR60, 51

SANDVIK 25.10.4L ... Argon +30% He +5% C02 ................ AR61, 54

#l85 ......... 1 . Omm ....... Stainless 253 MA ....... Argon +30% He +5% C02 ................ AR61, 54 #219 ......... 1.2mm ....... Stainless 253 MA ....... Argon +30% He +5% C02 ................ AR61, 54 # l 86 ......... 1.2mm ....... Stainless 253 MA ....... Argon - high purity ............................. Ar-HP #l81 ......... 0.9mm ....... Stainless 2RK65 ........ Argon +27% He ................................. AR80T, MS'TCB' #l 87 ......... 1.2mm ....... Stainless 2RK65 ........ Argon +30% He +5% C02 ................ AR61, 54 #l73 ......... 0.8mm ....... Stainless STA59 ........ Argon + l S% 0 2 ............................... AR60, 51 #l74 ......... 0.9mm ....... Stainless STA59 ........ Argon +l S% 0 2 ............................... AR60, 51

ALUMINIUM &ALLOYS SCHED DIAM MATERIAL GAS COMPOSITION GAS NAMES M 1 4 ......... 0.9mm ....... Aluminium 1100 ......... Argon ................................................ Ar # l 14 ......... 1.2mm ....... Aluminium 11 00 ......... Argon ................................................ Ar # l 15 ......... 1.6mm ....... Aluminium 11 00 ......... Argon ................................................ Ar # l 03 ......... 0.9mm ....... Aluminium 4043 ......... Argon ................................................ Ar #226 ......... 1 . Omm ....... Aluminium 4043 ......... Argon ................................................ Ar # l 04 ......... 1.2mm ....... Aluminium 4043 ......... Argon ................................................ Ar


#265 ........ 1.6mm ....... Aluminium 4043 ........ Argon - high purity ............................ Ar-HP # l41 ........ 1 .Omm ....... Aluminium 4047 ........ Argon ............................................... Ar #343 ........ 1.2mm ....... Aluminium 51 83 ........ Argon ............................................... Ar #435 ........ 1.2mm ....... Aluminium 51 83

SOFTARC USE CC OUTPUT .... Argon ............................................... Ar

#448 ........ 2.0mm ....... Aluminium 51 83 ........ Argon ............................................... Ar #371 ........ 2.4mm ....... Aluminium 51 83 ........ Argon ............................................... As #300 ........ 1.2mm ....... Aluminium 5183 ........ Argon +27% He ................................ AR8QT, MS'TCB'

#344 ........ 1.6mm ....... Aluminium 51 83 ........ Argon ............................................... Ar

#370 ........ 1.6mm ....... Aluminium 51 83 ........ Argon +27% He ................................ AR80T, MS'TCB' #249 ........ 1.2mm ....... Aluminium 5183 ........ Argon +75% He ................................ AR81T, MS'TCA' # l 07 ........ 0.8mm ....... Aluminium 5356 ........ Argon ............................................... Ar # l 08 ........ 0.9mm ....... Aluminium 5356 ........ Argon ............................................... Ar # l 09 ........ 1 .Omm ....... Aluminium 5356 ........ Argon ............................................... Ar # l 10 ........ 1.2mm ....... Aluminium 5356 ........ Argon ............................................... Ar #437 ........ l .2mm ....... Aluminium 5356

SOFTARC USE CC OUTPUT .... Argon ............................................... Ar

#312 ........ 2.4mm ....... Aluminium 5356 ........ Argon ............................................... Ar # l 11 ........ 1.6mm ....... Aluminium 5356 ........ Argon ............................................... Ar

# l 16 ........ 1.2mm ....... Aluminium 5356 ........ Argon +27% He ................................ AR80T, MS'TCB' # l 17 ........ 1.6mm ....... Aluminium 5356 ........ Argon +27% He ................................ AR80T, MS'TCB' # l 18 ........ 1.2mm ....... Aluminium 5356 ........ Argon +75% He ................................ AR81T, MS'TCA' #303 ........ 1.6mm ....... Aluminium 5356 ........ Argon +75% He ................................ AR81T, MS'TCA # l 05 ........ 1.2mm ....... Aluminium 5554 ........ Argon +27% He ................................ AR80T, MS'TCB' # l 06 ........ 1.6mm ....... Aluminium 5554 ........ Argon ............................................... Ar #341 ........ 1.2mm ....... Aluminium 5556 ........ Argon ............................................... Ar #342 ........ 1.6mm ....... Aluminium 5556 ........ Argon ............................................... Ar

, l ~

COPPER & ALLOYS SCHED DIAM MATERIAL GAS COMPOSITION GAS NAMES #212 ........ 0.9mm ....... De-ox Copper ....................... Argon +75% He ....................... AR81T, MS'TCA' #261 ........ 1.2mm ....... De-ox Copper ....................... Argon +75% He ....................... AR81T, MS'TCA' #307 ........ 1.2mm ....... De-ox Copper Extended ..... Argon +75% He ....................... AR81T, MS'TCA' #213 ........ 1.2mm ....... De-ox Copper ....................... Argon +27% He ....................... AR80T, MS'TCB' #302 ........ 1.6mm ....... Hulftegger SG-CuSn ............ Argon +75% He ....................... AR81T, MS'TCA' #306 ........ 1.6mm ....... Hulftegger SG-CuSn ............ Helium 100% ........................... HEL # l 01 ........ 1.6mm ....... Aluminium/Bronze A I ........... Argon ....................................... Ar # l 02 ........ 1.2mm ....... AluminiumlBronze A2 ........... Argon ....................................... Ar #229 ........ 1.2mm ....... Phosphor/Bronze ................. Argon ....................................... Ar # l69 ........ 0.8mm ....... Silicon Bronze ...................... Argon +OS% 02, Argon ........... AR70, ARXl , Ar #l70 ........ 0.9mm ....... Silicon Bronze ...................... Argon +OS% 02, Argon ........... AR70, ARXI. Ar

# l71 ........ 1 .Omm ....... Silicon Bronze ...................... Argon +OS% 02, Argon ........... AR70, ARXl , Ar #l72 ........ 1.2mm ....... Silicon Bronze ...................... Argon +0.5% 02, Argon ........... AR70, ARXI, Ar #l22 ........ 0.9mm ....... Monel 67 Cu-Ni 70/30 ........ Argon +27% He ....................... AR80T, MS'TCB' #l53 ........ 0.9mm ....... Monel 67 Cu-Ni 70/30 ........ Argon +0.7% 0 2 ...................... AR70, ARXl, Ar #l54 ........ 1.2mm ....... Monel 67 Cu-Ni 70/30 ........ Argon +0.7% 0 2 ...................... AR70, ARX'l, Ar #357 ........ 0.9mm ....... Monel 67 on CuNilO plate ... Argon +27% He ....................... AR80T, MS'TCB'

#362 ........ 0.9mm ....... Slhcon Bronze ...................... Argon ....................................... Ar ..

FLUX CORED WIRES SCHED DIAM MATERIAL GAS COMPOSITION GAS NAMES #423 ........ 1.2mm ....... AI 1760L .............................. Argon + l .5%02 W22 ........ 1.6mm ....... A! 1760L .............................. Argon + l .5%02 # l 19 ........ 1.2mm ....... Bohler 600 ........................... Argon + l 8% C02 .................... MI , CG18, AR51 #l20 ........ 1.6mm ....... Cobalarc 100-OP ................. Argon +l8% C02 .................... MI, CG18, AR51 #l21 ........ 1.2mm ....... Colmonoy 56

#l23 ........ 1.6mm ....... Colmonoy 56

#l48 ........ 0.9mm ....... Coreweld 70 ......................... Argon + l 8% C02 .................... MI, CG18, AR51

AI 1756 Ni/Cr/B ................... Argon +30% He +5% C02 ....... AR61, S4

AI 1756 Ni/Cr/B ................... Argon ....................................... Ar

SYNCHRQ-PULSE CDT 450 MANUAL

#l49 ......... 1.2mm ....... Coreweld 70 ......................... Argon +18% C02 .................... MI. CG18. AR51 #l50 ......... 1.6mm ....... Coreweld 70 ......................... Argon +18% C02 .................... MI. CG18. AR51

#223 ......... 1.6mm ....... Corodur 55 MOmig ............... Argon +7% 0 2 ........................ M4, CG07

#222 ......... 2.4mm ....... Corodur 61 ........................... Argon +7% 0 2 ........................ M4, CG07 #243 ......... 2.4mm ....... Corodur 68 ........................... Argon + l 5% 0 2 ...................... AR60, 51 #224 ......... 2.4mm ....... Corodur 300 MIG .................. Argon +7% 0 2 ........................ M4, CG07

#l36 ......... 1.2mm ....... Dual Shield 7000 .................. Argon +18% C02 .................... M I , CG18, AR51 #l37 ......... 1.6mm ....... Dual Shield 7000 .................. Argon +18% C02 .................... M I , CG18, AR51 #l31 ......... 1.2mm ....... Dual Shield 11-70 ................... Argon +18% C02 .................... M I , CG18, AR51 #210 ......... 1.2mm ....... Dual Shield 11-70 ................... Argon +25% C02 .................... M3, AR52 #211 ......... 1.6mm ....... Dual Shield 11-70 ................... Argon +25% C02 .................... M3, AR52 # l 32 ......... 1.2mm ....... Dual Shield 11-1 10 ................. Argon +l 8% C02 .................... M I , CG18, AR51

#l33 ......... 1.2mm ....... Fabloy 409 F.C ..................... Argon + I S % 0 2 ...................... AR60, 51 #346 ......... 1.Omm ....... Filarc PZ6125 ....................... Argon +18% C02 .................... M I , CG18, AR51 #l34 ......... 1.2mm ....... Fluxofil 11 Ni ......................... Argon +18% C02 .................... M I , CG18, AR51 #231 ......... 1.6mm ....... Fluxofil 11 Ni ......................... Argon +18% C02 .................... M1, CG18, AR51 #328 ......... 1.2mm ....... Fluxofil 11 Ni ......................... Argon +16% C02 +2.5% 0 2 ... AR51, CG2, M1 #274 ......... 1.6mm ....... Fluxofil 11 Ni ......................... Argon +16% C02 +2.5% 0 2 ... AR51, CG2, M I #268 ......... 1.2mm ....... Fluxofil 14 ............................. Argon +16% C02 +2.5% 0 2 ... AR51, CG2 #275 ......... 1.6mm ....... Fluxofil 14 ............................. Argon +16% C02 +2.5% 0 2 ... AR51, CG2 #276 ......... 1.6mm ....... Fluxofil 20 ............................. Argon +16% C02 +2.5% 0 2 ... AR51, CG2

#242 ......... 1.6mm ....... Corodur 42 ........................... Argon + l S% 0 2 ...................... AR60, 51

#221 ......... 1.6mm ....... Corodur 61 OA ..................... Argon +l 5% 0 2 ...................... AR60, 51

#l35 ......... 0.9mm ....... Dual Shield 7000 .................. Argon +18% C02 .................... M I , CG18, AR51

#259 ......... 1.6mm ....... EnDOtec DO*14 ................... Argon + I S % 0 2 ...................... AR60, 51

#331 ......... 1.6mm ....... Fluxofil 31 ............................. Argon +18% C02 .................... MI , CG18, AR51 #364 ......... 1.2mm ....... Fluxofil M42 .......................... Argon +16% C02 +2.5% 0 2 ... AR51, CG2

#232 ......... 1.6m rn ....... Hardface HC-G or HB-G ....... Argon +18% C02 .................... M I , CG18, AR51 #l 39 ......... 1.6mm ....... Fluxodur 1855 ....................... Argon + l . 5% 0 2 ...................... AR60, SI

#228 ......... 1.2mm ....... Metalcor XP .......................... Argon + l 8% C02 .................... M I , CG18, AR51 #280 ......... 1.2mm ....... Outershield 71 M Lincoln ....... Argon +16% C02 +2.5% 0 2 ... AR51, CG2 #281 ......... 1.6mm ....... Outershield 71 M Lincoln ....... Argon +l6% C02 +2.5% 0 2 ... AR51, CG2 #246 ......... 1.2mm ....... O/Shield MC 710 Lincoln ...... Argon +18% C02 .................... MI, CG18, AR51 #269 ......... 1.6mm ....... O/Shield MC 710 Lincoln ...... Argon +16% C02 +2.5% 0 2 ... AR51, CG2 #296 ......... 1.6mm ....... O/Shield MC 710 Lincoln ...... Argon +5% C02 +2% 0 2 ........ CG5.2, AR50 #264 ......... 1.2mm ....... Shld-Bright 309L ................... Argon +18% C02 .................... M I , CG18, AR51 #277 ......... 1.2rnm ....... Shld-Bright 309L ................... Argon +25% C02 .................... M3, AR52 #413 ......... 1.2mm ....... Staincored 316L .................... Argon +25% C02 .................... M3, AR52 # l 94 ......... 1.2rnm ....... Stellite No.6 STELLOY 6 ...... Argon +0.7% 0 2 ...................... AR70, ARXl , Ar # l 95 ......... 1.6mm ....... Stellite No.6 STELLOY 6 ...... Argon +0.7% 0 2 ...................... AR70, ARXl , Ar #230 ......... 1.6mm ....... Stellite No.21 ........................ Argon + l . 5% 0 2 ...................... AR60, 51 M 1 2 ......... 1.2mm ....... Stoody 101 HC-G ................. Argon +25% C02 .................... M3, AR52

#411 ......... 4.2mm ....... Tetra-S 309L-G ..................... Argon +l 8% C02 .................... MI, CG18, AR51 #201 ......... 1.3mm ....... Trimark TM771 ..................... Argon +18% C02 .................... M I , CG18, AR51 #202 ......... 1.6mm ....... Trimark TM771 ..................... Argon +18% C02 .................... M I , CG18, AR51 #278 ......... 1.2mm ....... Verticor 3XP ......................... Argon +16% C02 +2.5% 0 2 ... AR51, CG2 #279 ......... 1.6mm ....... Verticor 3XP ......................... Argon +16% C02 +2.5% 0 2 ... AR51, CG2 #299 ......... 1.2mm ....... Verticor 3XP ......................... Argon +25% C02 .................... M3, AR52 #292 ......... l . 6mm ....... Verticor 3XP ......................... Argon +25% C02 .................... M3, AR52

OTHER WIRE TYPES SCHED DIAM MATERIAL GAS COMPOSITION GAS NAMES #439 ......... 0.9mm ....... AUSMlG NiCrMo ERIIOS-G

SOFTARC USE CC OUTPUT ............... Argon +18% C02 .................... M I , CG18, AR51 #445 ......... 1.2mm ....... AUSTMIG TD600 ................. Argon +5% 02 ........................ CG05, AR40, AR'L

#l75 ......... 1.6mm ....... Stoody 130 ........................... Argon +18% C02 .................... MA, CG18, AR51

#260 ......... 1.6mm ....... Bohler DUR650-IG ................ Argon + l 8% C02 .................... MI, CG18, AR51 #352 ......... 1.2mm ....... Haynes Alloy 242 .................. Argon +27% He ....................... AR80T, MS'TCB' #233 ......... 1.2mm ....... lnconel 61 7 ........................... Argon +27% He ....................... AR80T, MS'TCB' #258 ......... 1 . Omm ....... Avesta P12A ......................... Argon +27% He ....................... AR80T, MS'TCB' #214 ......... 1.2mm ....... lnconel 625 ........................... Argon +27% He ....................... AR80T, MS'TCB8

I

SYNCHRO-PULSE CDT 450 MANUAL Paae 53 - #l42 ........ 1.6mm ....... lnconel 625 .......................... Argon +27% He ....................... AR80T, MS'TCB' #315 ........ 1.2mm ....... lnconel 625 .......................... Argon +30% He +5% C02 ....... AR61, S4 #l51 ........ 1.6mm ....... Magnesium AZ61A ............... Argon ....................................... Ar

#l62 ........ 1.2mm ....... Monel 60 Ni-Cu 70130 ......... Argon +0.7% 0 2 ...................... AR70, ARXl, Ar #319 ........ 0.8mm ....... Nickel 61 S9604 .................. Argon +0.7% 0 2 ...................... AR70, ARXl, Ar #l66 ........ 0.9mm ....... Nickel 61 S9604 .................. Argon +0.7% 02 ...................... AR70, ARX'I, Ar

#318 ........ 0.8mm ....... Monel 60 Ni-Cu 70/30 ......... Argon +0.7% 0 2 ...................... AR70, ARXl, Ar

#l67 ........ 1.2mm ....... Nickel 61 S9604 .................. Argon +0.7% 0 2 ...................... AR70, ARXl, Ar #333 ........ 0.9mm ....... Nicrofer S6020 ..................... Argon ....................................... Ar #l63 ........ 0.9mm ....... Nicrofer S6020 ..................... Argon +27% He ....................... AR80T, MS'TCB' #215 ........ 1.2mm ....... Nicrofer S6020 ..................... Argon +0.7% 0 2 ...................... AR70, ARXl, Ar #351 ........ 1.2mm ....... Nicrofer S7020

#217 ........ 1.2mm ....... Nicrofer S7020

#216 ........ 1.2mm ....... Nicrofer S7020

INCONEL 82 ....................... Argon +27% He ....................... AR80T, MS'TCB'

on MONEL 600 ................... Argon +27% He ....................... AR80T, MS'TCB'

on MONEL 600 ................... Argon +30% He +5% C02 ....... AR61, S4 #l64 ........ l .2mm ....... Nirod 44 ............................... Argon +7% 0 2 ......................... M4, CG07 # l 65 ........ 1.6mm ....... Nirod 44 ............................... Argon +7% 0 2 ......................... M4, CG07

#l68 ........ 1.2mm ....... Sanicro 72 ............................ Argon - high purity ................... Ar-HP

CONSTANT CURRENT MODE #205 ................ CC-Mode ......... 10-30A #204 ................ CC-Mode ......... 25-300A #203 ................ CC-Mode ......... 250-450A

G.M.A.W. MODE #208 ................ 0.9mm ............. CARBON STEEL..GMAW-DIP #209 ................ 1.2mm ............. CARBON STEEL..GMAW-DIP

#l76 ........ 1.2mm ....... Sanicro 27 on Sanicro 28 ..... Argon + l 5% 0 2 ...................... AR60, S1

#373 ................ 1.2mm ............. ALUMINIUM ......... GMAW ....................................... Argon Ar

This information is for Display Eprom #38146/60. Higher numbered Eproms may have additional Weld Schedules. For any requirements not shown in this list, please contact WIA or their representatives.

The codes used for proprietary gas names in the above list are.as follows:

H CG = Corgon;

AR = Argoshield;

H BS = Blueshield;

HEL = Helion;

m MS = Migshield;

ARX = Argonox;

H Ar - generic Argon;

Ar-HP = generic High Purity Argon.

-


15. PUSH-PULL GUN AND WIREFEEDER.

This appendix applies where the option for a push-pull wire-feeder system has been selected. The following table lists the alternative and additional parts which complete a push-pull installation:

Substitute wirefeeder type W35-4;

Substitute gun assembly type HT24-1 Hulftegger pull gun;

Additional torch neck as selected, HT24-l l straight, or HT24-12 curved;

Additional extension lead kit AM230-0/3;

Additional transistor heatsink assembly AM21 7-1, (supplied with the W35-4, and fitted to the CP38-16 wirespeed control pcb).

The remote pendant CP34-36/3 may optionally be deleted as the remote control function is available at the pull gun.

The W354 wirefeeder is fitted with a ‘Euro‘ gun adaptor and 10 pin control socket to suit the Hulftegger gun. It is adapted for aluminium welding applications having chrome-plated drive rollers and a nylon wire inlet guide.

All welding current, control and shielding gas connections for a push-pull installation are shown in Figure 24. Also given are details of the control cable wiring connections. PULL GUN SPEED CALIBRATION

To achieve correct operation of a push-pull wirefeed system, it is necessary to ensure that the wirefeed rate of the pull motor slightly ‘leads’ that of the push motor. In this way the consumable wire within the cable assembly is held in tension, so reducing drag on the wire.

Two speed adjustment potentiometers, marked “in’ and ‘Max’, are part of the CP38-16 board and protrude through the AM217-1 transistor/heatsink assembly. These are adjusted by the following method to obtain correct synchronisation of the Push and Pull feed motors. The steps require use of a digital tachometer with a surface speed wheel, and a 0-1 Amp DC meter.

Step l. Select OPTION > SERVICE > WIREFEED MIN. Adjust the “in’ potentiometer to obtain a surface speed of the Pull motor driven roller of 2.6 metres / min.

Step 2. Select OPTION > SERVICE > WIREFEED MAX. Adjust the ‘Max’ potentiometer to obtain a surface speed of the pull motor of 17.6 metres / min.

The motors may be further fine tuned by the following method. Step 3. Lay the gun cable out straight, and feed wire through the complete wirefeed

system. Fit the DC Ammeter in series with the pull motor using the red wire terminated on pull gun terminal strip. Again select OPTION > SERVICE > WIREFEED MINI and adjust the ”in’ potentiometer to obtain a pull motor current of approximately 400 mA.

Step 4. Select OPTION > SERVICE > WIREFEED MAX, and adjust the ’Max’ potentiometer to obtain a pull motor current of approximately 300mA.

~

SYNCHRO-PULSE CDT 450 MANUAL Page 55 n

C

Le!N PLUG

I t 2 + 3 t 4 + s t 6 t 7 t 8 t

3 PIN PLUG

2 + I + 3 t

GAS CYLINDER & REGULATOR

'WORK' CLAMP

W/F CONTROL CABLE REMOTE CONTROL CABLE W/F WELDING CABLE GUN CABLE ADAPTOR GREY VOLTAGE SENSE WIRE

4 EURO GUN q SWITCH SOCKET

8 CORE 8 PIN PLUG w35-4 10 PIN PLUG HT24-1 FLEX & SOCKET WIRE FEEDER & SOCKET PULL GUN

GREEN -+ BLACK RED \+ RED : G S h ? h ) - - / F \

RED/BLACK "5$ BLACK 0 (PUSH MOTOR) WHlTE-<y GREY - (VOLTAGE SENSE) BLUE ,-<y WHITE -< BROWN -<T ORANGE -< :g-zQ BLUE/WHITE \- SPARE CURRENT

GREEN/YELLOW ,-<+ BLACK - - - +

3 CORE 3 PIN PLUG FLEX &soc$ET rc;! (LHS)

BROWN - CURRENT -p<

ARC

BLUE - ARC LENGTH 4 3 - (RH9 GREEN - COMMON -<

8 LENGTH

FIGURE 25. CABLE AND HOSE CONNECTIONS FOR PUSH PULL.


PULL GUN CABLE ASSEMBLY


1 ........................... AM243-0/1 .......................... 10 Pin MS Connector 2 ........................... HT500-070 .......................... Knurled Nut for Euro Adaptor 3 ........................... HT300-332 .......................... Central Connector 4 .......................... .HT24-012 ............................. Wire Guide Sleeve 5 ........................... HT300-166/1 ....................... Nylon Liner, 8 metre 6 ........................... HT500-067 .......................... Coupling Nut M1 0x1 7 ........................... HT300-773 .......................... Control Cable 8 ........................... HT501.0073 ........................ Protective Sleeve 9 ......................... ..HT61 0-1 50 .......................... Protective Sheath 28x1 Smm 10 ......................... HT500-052 .......................... Press Connector 11 ......................... HT100-102 .......................... Press Nipple Low Pressure 12 ......................... HT300-730 .......................... Armoured Hose Connector 13 ......................... HT400.0101 ........................ Protective Sleeve 14 ......................... HT1 00-735 .......................... Hose Clip 16 ......................... HT300-834 .......................... Power Cable Assembly, 8 metre 17 ......................... HT300-837 .......................... Armoured Hose Assembly, 8 metre

ACCESSORY LEAD KIT AM223-9


1 ........................... AM230-0/1 .......................... Cannon Cord Socket, 3 pin Female 2 ........................... TC490-1 .............................. Cannon Cord Plug, 3 pin Male 3 ........................... CAB3C24SP ....................... 3 Core Flexible Cable

Note: These parts are in addition to the basic Accessory lead kit AM223, which is detailed in Section 13 of this Manual.

1 3

l -8 REMOTE -? CONTROL < CABLE

FIGURE 26. PULL-GUN CABLE ASSEMBLY AND CONTROL CABLE.

SYNCHRO-PULSE CDT 450 MANUAL Page 57 I

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r 27 1 &

24 7 26 3

!

36 "-----b

FIGURE 27- HULKEGGER GUN EXPLODED VIEW.


PULL GUN HULFTEGGER HC300

ITEM # PART # DESCRIPTION 1 ........................... HT300-743 .......................... Motor Block 2 ........................... HT300-100 .......................... Outlet Wire Guide 0.8-1.2mm ............................. HT300-109 .......................... Outlet Wire Guide 1.2-1.6rnm 3 ........................... HT300-024 .......................... '0' Ring 4 ........................... HT300-739 .......................... Central Gas Collector 5 ........................... HT300-732 .......................... Gasket Ring 6 ........................... HT300-025 .......................... ' 0' Ring 7 .......................... .HT300-759 .......................... Screw Cylindrical M4x8 8 ........................... HT300-745 .......................... Drive Roll Gate 9 ........................... HT300-765 .......................... Pressure Roller 0.8-1.2mm ............................. HT300-766 .......................... Pressure Roller 1.2-1.6mrn 10 ........................ .HT300-772 .......................... Axle for Ball Bearing 11 ......................... HT300-751 .......................... Pin Screw M4x25 12 ......................... HT300-747 .......................... Join for Pressure Lever 13 ....................... ..HT300-746 .......................... Pressure Adjusting Bracket Clip 14 ......................... HT300-757 .......................... Pin Screw M3x14 15 ......................... HT300-750 .......................... Pin Screw M4x18 16 ......................... HT300-769 .......................... Pressure Spring 17 ......................... HT300-053 .......................... Screw for Pressure Adjuster 18 ......................... HT300-461/3 ....................... Motor and Gearbox 19 ......................... HT300-064 .......................... Drive Key 20 ......................... HT300-059 .......................... Knurled Drive Roller 21 ......................... HT300-060 .......................... Drive Shaft Nut 22 ........................ .HT300-758 .......................... Cylindrical Screw M4x6 23 ......................... HT24-1 / l ............................. Potentiometer, 1 k6 24 ......................... HT300-717 .......................... Plastic Body, Upper 25 ......................... HT300-719 .......................... Protective Sleeve 26 ......................... HT300-711 .......................... Potentiometer Knob 27 ....................... ..HT300-727 .......................... Plastic Cover, Red 28 ......................... HT300-721 .......................... Trigger 29 ......................... HT300-068/3 ....................... Micro-switch with Wires 30 ......................... HT300-720 .......................... Gun Grip 31 ......................... HT300-716 .......................... Gun Body 32 ......................... HT300-753 .......................... Cylindrical Screw M4x30 33 ........................ .HT300-049 .......................... Cylindrical Screw M4x6 34 ......................... HT300-026 .......................... Inlet Wire Guide 0.8-1.2mm ............................. HT300-l I O .......................... Inlet Wire Guide 1.2-1.6mm 35 ......................... HT300-754 .......................... Screw M3x10 36 ......................... HT300-755 .......................... Screw M4x8 37 ......................... HT310-200 .......................... Locknut

l

SYNCHRO-PULSE CDT 450 MANUAL Page 59 -

HT24-l l STRAIGHT TORCH NECK


1 .......................... HT24-11/1 ........................... Neck Adaptor 2 .......................... BE4780 ............................... Insulator 3 .......................... HT24-11/2 ........................... Straight Body 4 .......................... BE4423 ............................... Insulating cap 5 .......................... BE4635-1 16 ........................ Head Assembly 6 .......................... BE4492 ............................... Nozzle assembly 7 .......................... BE1590 ............................... Contact Tip 1.2mm 8 .......................... HT310-077 .......................... Wire Guide

mg&&h HT24-l2 CURVED TORCH NECK


1 HT24-11/1 Neck Adaptor 2 .......................... BE4780 ............................... Insulator 3 .......................... HT24-12/1 ........................... Curved Body 4 .......................... BE4423 ............................... Insulating cap 5 .......................... BE4635-116 ........................ Head Assembly 6 .......................... BE4492 ............................... Nozzle assembly

.......................... ...........................

7 .......................... BE1590 ............................... Contact Tip 1.2mm 8 .......................... HT300-806 .......................... Wire Guide

v

FIGURE 28. TORCH NECK ASSEMBLIES.

SYNCHRO-PULSE CDT 450 MANUAL v

W354 PUSH PULL WIREFEEDER ASSEMBLY.


1 ........................... W35-14 ............................... Case Assembly 2 ........................... AM1 77 ................................ Spool Holder Assembly

4 ........................... AM138-2 ............................. Plastic Dust Flap 5 ........................... W25-0 ................................. Wirefeed Motor and Drive Assembly

3 ........................... W21-11/9 ............................ Dust Flap Mounting Rod

Including 5.1 ................... W1 7-01 /6 ............................ Wirefeed Motor 5.2 ................... W2-44 ................................. Two Roll Drive Assembly 5.3 ................... W2-49 ................................. Flat Drive Roller, Chromed 5.4 ................... W2-48 ................................. Grooved Drive Roller, Chromed 5.5 ................... W2-44/12-1N ....................... Input Wire Guide, Nylon

6 ........................... K34 ..................................... Cannon Socket, 8 Pin 9 .......................... .TC262 ................................. Gas Inlet 10 ......................... TC262N ............................... Nut 19 ......................... K57 ..................................... Cannon Socket, 10 Pin MS 20 ......................... AM217-1 ............................. Transistor Heatsink Assembly

21 ......................... W35-4/1 .............................. Cannon socket, 3 Pin Male 22 ......................... TC396-5 .............................. Euro Gun Adaptor

(Fitted to CP38-16 Wirefeed board)

@TRANSISTOR HEATSINK ASSEMBLY

FIGURE 29. PUSH PULL WIREFEEDER ASSEMBLY W35-4.


16. SAFE PRACTICES.

These notes are provided in the interests of improving operator safety. They should be considered only as a basic guide to Safe Working Habits. A full list of Standards pertaining to industry is available from the Standards Association of Australia, also various State Electricity Authorities, Departments of Labour and Industry or Mines Department and other Local Health or Safety Inspection Authorities may have additional requirements. WTlA Technical Note TN7-98 also provides a comprehensive guide to safe practices in welding.

EYE PROTECTION NEVER LOOK AT AN ARC WITHOUT PROTECTION. Wear a helmet with safety goggles or

glasses with side shields underneath, with appropriate filter lenses protected by clear cover lens. This is a MUST for welding, cutting, and chipping to protect the eyes from radiant energy and flying metal. Replace the cover lens when broken, pitted, or spattered.

Recommended shade filter lens.

Amps TIG MMAW MIG Pulsed MIG 0-100 ............. 10 .................. 9 ................... 10 ................. 12-13 100-150 ......... l 1 .................. 10 ................. I O ................. 12-13 150-200 ......... 12 .................. 10-11 ............ 11-12 ............ 12-13 200-300 ......... 13 .................. 11 ................. 12-13 ............ 12-13 300400 ......... 14 .................. 12 ................. 13 ................. 14 400-500 ............................ " 13 ................. 14 ................. 14 500 * ................................................... " " 14 ................. 14

BURN PROTECTION. The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight

clothing, reflect from light-coloured surfaces, and bum the skin and eyes. Bums resulting from gas- shielded arcs resemble acute sunbum, but can be more severe and painful.

Wear protective clothing - leather or heat resistant gloves, hat, and safety-toe boots. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag.

Avoid oily or greasy clothing. A spark may ignite them. Hot metal such as electrode stubs and work pieces should never be handled without gloves.

Ear plugs should be worn when welding in overhead positions or in a confined space. A hard hat should be wom when others are working overhead.

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

TOXIC FUMES. Adequate ventilation with air is essential. Severe discomfort, illness or death can result from fumes,

vapours, heat, or oxygen depletion that welding or cutting may produce. NEVER ventilate with oxygen. Lead, cadmium, zinc, mercury, and beryllium bearing and similar materials when welded or cut may

produce harmful concentrations of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be used.

Metals coated with or containing materials that emit fumes should not be heated unless coating is removed from the work surface, the area is well ventilated, or the operator wears an air-supplied respirator.

Work in a confined space only while it is being ventilated and, if necessary, while wearing air- supplied respirator.

Paae 62 SYNCHRO-PULSE CDT 450 MANUAL U

Vapours from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly toxic gas, and lung and eye irritating products. The ultra-violet (radiant) energy of the arc can also decompose trichlorethylene and perchlorethylene vapours to form phosgene. Do not weld or cut where solvent vapours can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichlorethylene or percholorethylene.

FIRE AND EXPLOSION PREVENTION. Be aware that flying sparks or falling slag can pass through cracks, along pipes, through windows or

doors, and through wall or floor openings, out of sight of the operator. Sparks and slag can travel up to 10 metres from the arc.

Keep equipment clean and operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause short circuits.

If combustibles are present in the work area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work can not be moved, move combustibles at least 10 metres away out of reach of sparks and heat, or protect against ignition with suitable and snug-fitting fire-resistant covers or shields.

Walls touching combustibles on opposite sides should not be welded on or cut. Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields.

A person acting as Fire Watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if;

Combustibles (including building construction) are within 10 metres.

w Combustibles are further than 10 metres but can be ignited by sparks.

Openings (concealed or visible) in floors or walls within 10 metres may expose combustibles to sparks.

Combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or

After work is done, check that area is free of sparks, glowing embers, and flames. conducted heat.

A tank or drum which has contained combustibles can produce flammable vapours when heated. Such a container must never be welded on or cut, unless it has first been cleaned as described in 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 vapours.

SHOCK PREVENTION. Exposed conductors or other bare metal in the welding circuit, or ungrounded electrically alive

equipment can fatally shock a person whose body becomes a conductor. Ensure that the machine is correctly connected and earthed. If unsure have machine installed by a qualified electrician. On mobile or portable equipment, regularly inspect condition of trailing power leads and connecting plugs. Repair or replace damaged leads.

Fully insulated electrode holders should be used. Do not use holders with protruding screws. Fully insulated lock-type connectors should be used to join welding cable lengths.

Terminals and other exposed parts of electrical units should have insulated knobs or covers secured before operation.

SYNCHRO-PULSE CDT

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FIGURE 16. CDT 450 POWER SOURCE ASSEMBLY CP38-3.

MODEL /oo - welding.com.au

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