WELDING INDUSTRIES OF AUSTRALIA LTD 004 547 1

WELDING INDUSTRIES OF AUSTRALIA A DIVISION OF WELDING INDUSTRIES LTD

ACN 004 547 1 l l

Head Office and International Sales

5 Allan Street, Melrose Park

South Australia, 5039

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

OWNERS MANUAL

WELDMATIC FOUR ROLL DRIVE

ENCLOSED WIREFEEDER

MODEL NO. W41-l, REV. B 12/98

QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICE 4 5

WELDMATIC W41-l WIREFEEDER MANUAL

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 number of the machine and part number of the item required. All relevant numbers are shown in lists contained in this manual. Failure to supply this information may result in unnecessary delays in supplying the correct parts. SAFETY

Before this equipment is put into operation, the Safe Practices section at the back of the manual must be read completely. This will help to avoid possible injury due to misuse or improper welding applications. PLASTIC HANDLE

intended for carrying the machine by hand only.

manner.

Please note that the handle fitted to the WELDMATIC W41-1 WIREFEEDER is

DO NOT use this handle for suspending or mounting the machine in any other

CONTENTS

Sec.1 ................... Introduction .................................................... P.3 Sec.2 ................... Receiving ....................................................... P.3 Sec.3. .................. Specifications ................................................ P.3 Sec.4.. ................. Wirefeeder Controls ...................................... P.4 Sec5 ................... Installation ..................................................... P.5 Sec.6 ................... General Maintenance .................................... P.6 Sec.7 ................... Wirefeeder Assembly .................................... P.8 Sec.8. .................. Service Information.. ...................................... P. 1 Q Sec.9 ................... Parts Lists. ..................................................... P. 1 l Sec. I O ................. Safe Practices ............................................... P. 14

FIGURES

Fig.1 .................... Wirefeeder Controls ...................................... P.4 Fig.2 .................... Connection to Power Source ......................... P.5 Fig.3 .................... W41-1 Wirefeeder Assembly ......................... P.9

Fig.5 .................... Gun Cable Assembly ..................................... P.1 1 Fig.6 .................... Wire Drive Assembly ..................................... P. 12 Fig.7 .................... Inter-Connecting Lead Kit .............................. P. 13

Fig.4 .................... Wirefeeder Circuit Diagram ........................... P. I O

WELDMATIC W41-1 WIREFEEDER MANUAL

l. INTRODUCTION

Gas Metal Arc Welding (G.M.A.W.) is basically a simple welding process, where a consumable wire is fed by motor driven rollers to a welding gun and 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 arc and the weld pool are both shie.lded by gas flow from the gun, or in the case of ‘self shielded’ wires, by gases generated by the wire core.

The process is quite versatile in that by selecting the correct wire composition, diameter and shielding gas, it can be used for applications ranging from sheetmetal to heavy plate, and metals ranging from carbon steel to aluminium alloys.

The WELDMATIC W41-1 WIREFEEDER has been designed to feed a range of hard, soft, and flux-cored wires for the Gas Metal Arc Welding process. A compact motor with integral gear box is coupled to a four roll drive assembly forming the basic component of the wire feeder. The motor is controlled by an electronic speed control which ensures excellent speed regulation over the full torque range of the motor, with inherent compensation for supply voltage variations.

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 W41-1 package contains; W41-1 Enclosed Wirefeeder. AM282-0/10 Inter-connecting lead kit, 10 metre. (This) Owners Manual.

3. SPECIFICATIONS

SUPPLY VOLTAGE 30 volts AC, (from welding power source)

RATED SUPPLY CURRENT 5 Amps

FUSE RATING 5 Amps

PRE-GAS RANGE 0 - l .2 seconds

POST-GAS RANGE 0 - 2.5 seconds

BURNBACK RANGE 0 - 0.07 seconds

START SPEED Normal or Reduced (switchable)

DIMENSIONS L - 610mm, W - 200mm, H - 420mm

MASS 33Kg (including Lead Kit)

SPOOL SIZES 5Kg, 15Kg

WIRESPEED RANGE 0 - 190 RPM (0 - 18 Metres per min.)

WIRE SIZE RANGE 0.9mm - 1.2mm diameter (solid wire) 1.2mm - 1.6mm diameter (cored wire)

Paae 4 WELDMATIC W41-l WIREFEEDER MANUAL

4. WIREFEEDER CONTROLS

FIGURE l. WIRE FEEDER CONTROLS

1. WIRE SPEED CONTROL This control sets the speed of the wire drive motor within the range of 0 - I90 RPM,

equivalent to 0 - 18 metres per minute of welding electrode wire. Rotate the control clockwise to increase the feed rate. 2. POWER ON INDICATOR

the power source is switched on. 3. INCHIPURGE SWITCH

flow rate, or purge gas lines.

power source contactor.

This indicator is illuminated when wirefeeder is connected to a power source and

From the central switch position, lift this switch to energise the gas valve to set gas

Depress this switch to run the wire drive motor without energising the welding

4. PRE-GAS CONTROL This control sets the time period of gas flow before welding commences, and may

be adjusted from 0 - 1.2 seconds. 5. POST-GAS CONTROL

This control sets the time period of gas flow after welding ceases, and may be adjusted from 0 - -l .2 seconds. 6. BURNBACK CONTROL

released, and wirefeed ceases, and may be adjusted from 0 - 0.7 seconds. 7. START SPEED SWITCH

NORMAL (up) is selected for immediate starts, as required for tacking, short welds, etc. REDUCED (down) is selected for softer starts, as required when welding aluminium, etc.

This control sets the time period that welding continues after the gun switch is

This switch controls the start up speed of the wirefeeder;


INSTALLATION

The WELDMATIC W41-1 WIRE FEEDER is supplied with a lead kit consisting of:

WELDING CABLE

WORK LEAD

CONTROL CABLE

GAS HOSE Connections are shown in Figure 2. Check all connections are firmly made to

ensure good electrical contact, and to eliminate gas and air leaks. Check that the wire guide and drive rollers fitted are appropriate to the electrode

wire to be used. For optional combinations, see Section 8. Standard wirefeeders are factory fitted with a W51-0/2 bottom roller, and plain top roller, which are suitable for both 0.9mm and 1.2mm diameter steel wire.

GAS CYLINDER & REGULATOR

\GAS HOSE W/F WELDING CABLE

CONTROL CABLE

FIGURE 2. CONNECTIONS TO P-OWER SOURCE

P a m 6 WELDMATIC W41-1 WIREFEEDER MANUAL

7. GENERAL MAINTENANCE

OPERATOR CHECKS

If the wire feeder motor will not turn when gun switch is operated and speed control is set to desired speed, check the following points;

1. Ensure that 30 Volts A.C. power is available at wirefeeder and Power Indicator is lit. Check fuse located on power source front panel ( I O Amp) and check fuse located on wirefeeder printed circuit board (5 Amp).

2. Operate ‘INCH’ switch. If motor turns, fault may be either in gun switch or the switch wires in the gun cable. If motor does not turn, check connections to motor and visually check printed circuit board ensuring that all components, wiring and electrical connections are secure.

If wirefeeder fuses fail repeatedly while welding, check the following points;

1. Check tension of spool holder or wire reel brake, Reel or spool should only have sufficient pressure applied to prevent over run when motor stops.

2. Ensure feed roll pressure is only sufficient to push wire evenly. Excessive pressure can deform electrode wires.

3. Ensure wire feed liner is clean. Blow out or replace if necessary. 4. Ensure tip is free of obstructions, ream out if necessary. Replace tip when

5. Ensure wire is straight and free of buckles. 6. Ensure wire is free of rust, replace if necessary. 7. Ensure feed roll gear teeth are free of interfering material.

oversize.


FITTING THE GUN CABLE

The BERNARD BEXT2-4E350AE gun cable is equipped with a 'Euro' wirefeeder connector which incorporates all required connection points to the gun cable for welding current, shielding gas and gun switch control.

To attach the gun cable to the wirefeeder mechanism, engage the mating parts of the male and female Euro connectors, then rotate the locking ring clockwise to firmly secure the connection.

FITTING THE CONSUMABLE WIRE

The quality of the consumable wire greatly affects how reliably a gas metal arc welder will operate. For best results when welding mild steel, we recommend quality WIA AUSTMIG ES6. Dirty, rusty or kinked wire will not feed smoothly through the gun cable and will cause-erratic welding. Deposits from the wire will clog the gun cable liner requiring it to be replaced prematurely.

Place the spool of welding wire onto the spool holder. The location pin should mate with a hole provided on 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 the Nyloc nut using a 15/16" AF or 24mm socket wrench.

FEEDING THE CONSUMABLE WIRE / WIRE INCH

With reference to Figure 6, release the pressure screw fixing shaft (1 g), and rotate the pressure arms (16) to the open positions. The end of the welding wire can now be passed through the inlet guide, over the bottom driven rollers, and into the output wire guide tube, Check that the drive roller grooves are correct for the wire in use. The appropriate size is stamped on the visible side of the installed roller. Check also that the correct size contact tip is fitted at the gun end. Drive roller and tip details are available in Section 8 of this manual.

Return the pressure arms to the closed position and adjust the compression screw to provide sufficient clamping of the drive rolls to achieve constant wirefeed. Do not over tighten.

With the machine energised, operate the INCH switch to feed wire through the gun cable.


7. WELDMATIC W41-l WIREFEEDER

ITEM # PART # DESCRIPTION

1 ....................... W41 -1 0.. ....................... Wirefeeder Control PCB 2 ....................... W4 1-20Y ...................... Base Panel 3 ....................... W4 1-22Y ...................... Front Panel 4.. ..................... W39-13Y ...................... Back Panel 5 ....................... W39-14Y ..................... .Top/Side Panel 6.. ..................... W39-15Y .................... ,.Door Panel 7 ....................... W39-16Y ...................... Divider Panel 8 ....................... W51 -1 ........................... Motor & 4 Roll Drive 9 ....................... W41-24 ........................ .Insulating Washer (2) I O ..................... W41 -25 ......................... Mounting Insulator (2) 11 ..................... TC396-7 ....................... Euro Gun Adaptor 12 ..................... CP101-0/18 .................. Gas Valve 13. .................... W1 1-1 1 /l ..................... .Hose Tail (2) 14 ..................... OCL8 .......................... ..IO’ Clip 8mm 15 ..................... AMI 77 ........................ ..Spool Holder Assembly

Includes 15.1 ............... AM133-3 ....................... ‘R’ Clip

16 ..................... W41-28 ......................... Power Loom 17.. ................... W41 -29.. ....................... Control boom

Includes 17.1 ............... W1 7-011 1 ...................... Indicator Light 17.2. .............. CP34-36/2 .................... Wirespeed Potentiometer

18 ..................... HF200-1/15 .................. Mounting Foot (4) 19.. ................... MC36-56/21 .................. Male Bush 20 ..................... CP5-0/8 ........................ Female Bush 21 ..................... H907 ............................. Cable Clamp 22 ..................... W41 -0/1 ........................ Hinge L. H. 23 ..................... W41-0/2 ........................ Hinge R.H. 24.. ................... W29-1/20, ................... ..Slam Action Latch (2) 25.. ................... W1 7-0/13.. ................... .Inch/Purge Switch 26.. ................... W1 1 -0/16... ................... Potentiometer Knob 27 ..................... S140-0/1 ....................... Handle 28 ..................... WIN281 ........................ Front Label 29 ..................... WIN273 ........................ Side Label (2) 30 ................... ..CP102-0/18 .................. PCB Support (4) 31 ..................... RUB16SQA .................. Insulation Guard 32 ..................... WIN286 ........................ Internal Label


c

FIGURE 3. W41-l WIREFEEDER ASSEMBLY

Paae I O WELDMATIC W41-1 WIREFEEDER MANUAL

8. SERVICE INFORMATION

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FIGURE 4. WIREFEEDER CIRCUIT DIAGRAM

WELDMATIC W41-1 WIREFEEDER MANUAL Paae I 1

9. PARTS LISTS

BEXT2-4E350AE GUN ASSEMBLY

1 .... BE4591 ........... Nozzle 15 .. BE4E213B ....... End Fitting 2 .... BE1597 ........... Contact Tip 0.6mm 16 .. BE4305 ........... Cone Nut ...... 5E1588 ........... Contact Tip 0.8mm 17 .. BE2660001 ...... Terminal ...... BE1589 ........... Contact Tip 0.9mm 18 .. BE7669 ........... Clamp ...... BE1590 ........... Contact Tip 1.2mm 19 .. BE252001 7 ...... Strain Relief, Flexible

3 .... BE4635-1 16 ..... Head 20 .. BE1470007 ...... Bushing 4 .... BE4423R ......... Cap 21 .. BE1 780055 ...... Strain Relief, Rigid 5 .... BE4780 ........... Nut Insulator 22 .. BE2280002 ...... Screw 6 .... BE1370117 ...... Insulator 23 .. H2072 .............. Insulated Link 7 .... BE1370116 ...... Body Tube 24 .. BE4816 ........... Nut 8 .... BE1 780006 ...... Handle Kit 25 .. BE5060 ........... Euro Block 9 .... BE5662 ........... Trigger 26 .. BE4421 ........... ‘0’ Ring 10 .. BE1 880004 ...... Screw Kit 27 .. BE441 15 ......... Liner 0.9 - 1.2mm 14 .. BE8681TE ....... Cable 3M.

To replace liner: Disconnect gun cable assembly from the Euro adaptor on the machine case, remove nozzle (l) and head (3). Withdraw old liner from the wirefeeder end. Insert new liner and refit gun cable assembly to Euro adaptor on the machine case. At the gun end, compress the liner within the gun cable, then cut it one contact tip length past the end of the body tube (7). Refit head, tip and nozzle.

FtGURE 5. BEXT2-4E350AE (350 AMP) GUN CABLE ASSEMBLY

Page I 2 WELDMATIC W41-l WIREFEEDER MANUAL

W51-0. FQUR ROLL DRIVE ASSEMBLY

ITEM # PART # DESCRIPTION

1 .......... W51 -0/11 ...... Feed Plate 2 ......... .W51 -0/12 ...... Gear Wheel 3 ......... .W51 -0/13 ...... Fixing Cap 4 , , , , , . , , . . W51 -0/14 . , . . ,.Screw M4x12 5. ......... W51 -0/15 ...... Woodruffs Key 3x6.5 6 .......... W36-0/17 ...... Motor & Gearbox 7 ......... .W51 -0/17 ...... Bronze Bearing (8)

9, ......... W51 -0/19 ...... Parallel Key 4x4.8 (2) 10 ........ W51-0/2 ........ Feed Roll 0.9mm+l.2mm “ V ’ 1 l ........ W51 -0/20 ...... Fixing Cap (2) 12 ........ W51 -0/21 ...... Shaft (2) 13 ........ W51-0/22 ...... Gear Wheel Complete (2) 14 ........ W51 -0/23 ...... Circlip (2)

8 .......... W51-0/18 ...... Gear Wheel (2)

15 ....... .W51 -0/24 ...... Shaft (2) 16 ........ W51-0/25 ...... Pressure Arm (2) 1 7 ........ W51 -0/26 ...... Shaft (2) 18 ........ W51-0/27 ...... Intermediate Guide 19 ........ W51-0/28 ...... Fixing Arm 20 ........ W51-0/29 ...... Calibrated Collar 21 ........ W51 -0/30 ...... Pressure Spring 22 ........ W51-0/31 ...... Cap for Fixing Shaft

23 ........ W51-0/32 ...... Circlip (2) 24 ........ W51-0/33 ...... Inlet Guide 25 ........ W51-0/34 ...... Wire Guide Tube 26 ........ W51-0/35 ...... Motor & Gearbox 27 ........ W51-0/36 ...... Pressure Arm Spring 28 ........ W51-0/37 ...... Circlip (2) 29 ........ W51-0/38 ...... Screw M6x16 (3) 30 ........ W51-0/39 ...... Circlip (3) 31 ........ W51-0/40 ...... Screw M6x6 (2)

ALTERNATIVE PARTS

(IO) ..... W51-0/3 ........ Feed Roll 0.9mm+l.2mm “U” (10) ..... W51-0/1 ........ Feed Roll 1.2mm+I .6mm Knurled (IO) ..... W51-0/4 ........ Feed Roll 0.8rnm+l .Omm “ V (IO) ..... W51-0/5 ........ Feed Roll 0.6mm+0.8mm “V”

FIGURE 6. W51-0 FOUR ROLL DRIVE ASSEMBLY

L

WELDMATIC W41-1 WIREFEEDER MANUAL Paae 13

AM282-0/10 INTER-CONNECTING LEAD KIT

ITEM # .................. PAaT # ............................... DESCRIPTION

1 ........................... AM282-1/10 ......................... Work bead

1 .l ........................ CABW50 ............................. Welding Cable 50mm2 1.2 ........................ cx21 ................................... Plug 1.3 ........................ C232-CM ............................. Work Clamp 1.4 ........................ H1423 ................................. Crimp Lug

2 .......................... .AM282-2/10. ........................ Weld Lead

2.1 ........................ CABWSO ............................. Welding Cable 50mm2

2.3 ........................ H1422 ................................. Crimp Lug

3 ........................... AM282-3/1 Q ......................... Control Lead

3.1 ........................ CAB4C32 ............................ Cable 4 Core 3.2 ........................ AM1 12-3/1 ........................... Control Plug

3.4 ...................... ..H1 138 ................................. Insulator (4)

4 .......................... .AM282-4/10 ......................... Gas Hose

4.1 ........................ 62513 .................................. Gas Hose 5mm 4.2 ........................ OCLl3 ................................. ‘0’ Clip 1/2” (2)

Includes

Includes

2.2 ........................ cx21 ................................... Plug

Includes

3.3 ........................ H1972ET ............................. Quick Connect Lug Female (4)

Includes

WORK LEAD

WELD LEAD AM282-2/ 10

CONTROL L E D

GAS HOSE pl”282-4/10

FIGURE 7. AM282-0/10 INTER-CONNECTING LEAD KIT


IO. SAFE PRACTICES WHEN USING WELDING EQUIPMENT

These notes are provided in the interests of improving operator safety. They should be considered only as a basic guide to Safe Working Habits. A full list of Standards pertaining to industry is available from the Standards Association of Australia, also various State Electricity Authorities, 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.

€YE 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 M E Pulsed MIG 0-100 ............ IO ................. 9 ................... 10 ................. 12-13 100-150 ......... 11 ................. 10 ................. IO ................. 12-13 150-200 ......... 12 ................. 10-11 ............ 11-12 ............ 12-13 200-300 ......... l 3 ................. 11 ................. 12-13 ............ 12-13 300400 ......... 14 ................. 12 ................. 13 ................. 14 400500 ............................ " 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 burn the skin and eyes. Burns resulting from gas- shielded arcs resemble acute sunburn, but can be more severe and painful.

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

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

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

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

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

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

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

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

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

WELDMATIC W41-l WIREFEEDER MANUAL Page l 5

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.

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

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

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

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

WELDING INDUSTRIES OF AUSTRALIA LTD 004 547 1

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