WELDMATIC 3 2 0

MODEL NO. CP26

CAT. 7 5 2 3 / 2 6

1 / 8 0

THE INFORMATION CONTAINED IN THE FOLDER IS SET OUT TO ENABLE YOU TO PROPERLY MAINTAIN YOUR NEW EQUIPMENT AND ENSURE THAT YOU OBTAIN MAXIMUM OPERATING EFFICIENCY.

PLEASE ENSURE THAT THIS FOLDER IS KEPT IN A SAFE PLACE FOR READY REFERENCE WHEN REQUIRED.

WHEN REQUESTING SPARE PARTS, QUOTE THE MODEL NO. AND SERIAL NUP4BER OF THE MACHINE AND THE PART NO. OF THE ITEM REQUIRED.

DELAYS IN SUPPLYING THE CORRECT PARTS. FAILURE TO SUPPLY THIS INFORMATION WILL RESULT IN UNNECESSARY

WELDING INDUSTRIES OF AUSTRALIA PTY. LTD.

Melbourne 4 2 9 4 7 6 6 Sydney 5 3 4 2 1 4 4 Newcastle 6 1 1668 Adelaide 3 5 2 3 0 2 2 Perth 3 6 1 7 0 8 8 Brisbane 4 4 1 3 9 1 Launceston 31 7 0 0 4 Darwin 8 1 6 4 2 7 & 8 4 3 0 7 6 .

OPERATING AND MAINTENANCE INSTRUCTIONS WELDMATIC 320 (,CP26)

INTRODUCTION GENERAL This manual has been prepared especially for use in familiarizing personnel with the design, installation, operation, maintenance, and troubleshooting of this equipment. All information presented herein should be given careful consideration to assure optimum performance of this equipment.

RECEIVING/HANDLING Prior to installing this equipment, clean a11 packing material from around the unit and carefully inspect for any damage that may have occurred during shipment. Any claims for losses or damage that may have occurred in transit must be filed by the purchaser with Welding Industries of Australia Pty. Ltd. or authorised agent immediately (refer to EQUIPMENT WARRANTY card enclosed with Operating Instruction Manual).

When requesting information concerning this equipment, it is essential to supply correct Model identification and machine serial number.

SAFETY. Before the equipment is put into operation, the SAFETY PRACTICES section at the back of this manual MUST BE READ COMPLETELY. This will help avoid possible injury due to misuse or applications.

CONTENTS General Description

Setting up for Operation

Welding Operation Instructions

Maintenance Instructions

Welding Data - Table "C" - Parts List CP 25-03 Issue 4 - Assembly Drawing CP 25-03 Issue 4

Circuit Diagrams - CP25-C4 Mobile Kit Assembly - AM51

Safety Practices

Guarantee Card

improper welding

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STANDARD U N I T The construction of the standard package plant has been designed for installation and operating in a wide variety of applications, such as high production factories and general fabrication shops.

"WELDMATIC" Plants consist of three basic units :-

l. Constant Potential Rectifier Power Source 2. Semi-Automatic Wire Feeder 3. Welding Gun and Cable Assembly.

Separate operating and maintenance instructions are provided for the wire feeder and gun cables.

1. POWER SOURCE - FEATURES

The standard C.P. rectifier power source is housed in a drip proof enclosure. Lifting lugs are provided for crane transportation. For units with wheel mounting, four solid rubber tyred wheels are provided; the two front wheels are steerable permitting easy move- ment in restricted floor space. A push bar is provided on the front of the machine and a gas cylinder carrier with a support bracket and chain at the rear. A 110 volt plug socket is located on the rear panel for connection of gas preheater when welding with C02 gas shield. Located on the front panel are a coarse voltage selection switch (incorporating power ON/OFF), fine volt- age selection switch, control fuses, wire feeder plug socket and rectifier power outlet sockets.

2. CONSTRUCTION The power source is a Constant Potential Silicon Diode Rectifier D.C. Welder, with a three phase transformer and a three phase rectifier bridge. Connected in the output circuit is an induct- ance unit providing the "inductance" or degree of slope necessary for various welding currents. Cooling of the silicon diodes, transformer windings and inductance unit is by a single phase axial fan. The power source is protected against fan failure and overheating by thermostats mounted on diode heat sinks.

3. WELDING PROCESS Gas metal arc welding within the capacity Of the Power Source can be carried out with the following equipment:- a) Sem.i-automatic wire feeder model W14. b) Semi-automatic wire feeder with spot timer W14-20 C) "Hobart" spool gun welding unit model SP9 with CV2 Controller. d) "Mini-mig" push and pull gun and control.

4. WELDING CAPACITY Power Source Capacity is as follows:-

320 Amps, 25 volts, 100% duty cycle.

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5 SUPPLY AND WELDING CABLES.

Power Sources are suitable for connection to a 415 vol t 50 Hertz 3 phase supply.

The recormended fuse size, primary cable size and welding cable s ize are as follows:-

a ) Fuse - l 5 amp. b ) Primary Cable - 4 core 30/0.25 T.R.S. c ) Welding Cable - 1121/0.20 T.R.S.

Q. SHIELDING GASES.

a ) Welding Grade C02 f o r a l l mild and al loy s teel welding i n

b ) Argon/CQ2 or Argon/Oxygen mixtures for al l applications on thicknesses ranging from l m r n upwards.

low currents requiring minimum of spat ter om sheet s teel and fo r s t a in l e s s s t ee l welding.

of s ta in less s tee l . c ) Argon/Oxygen and Argon/C02 mixtures for prime quality welding

d ) Argon (pure) for a l l aluminium welding.

7 . SETTING W UNIT FOR OPERATION,

a ) General Assembly of Packaqed Plant (Refer Drawing AM511 The Rectifier Welder i s shipped w i t h the skids or wheels unbolted. Bolt- on the wheel assemblies w i t h the steerable ( swive l ) wheels nearest the front panel and push bar. I f a "Mini-Boom" wire feeder mounting is supplied, locate the vertical boom post i n the special swivel mount a t the rear af the machine. Locate the Wire Feeder on the swivel mount, ensuring t h a t the f ibre thrust washer i s on the pivot pin. Check that the "Wire Feeder" i s f r ee t o swivel i n a l l directions. If necessary apply a small amount of graphite grease to shaft .

b) Connection t o Mains Supply.

Note: T h i s work should only be done by a qual i f ied e lectr ic ian. The power source i s designed €or connection t o 415 vol t , 50 hertz , 3 phase supply and the supply voltage should be ascert- ained before connecting the machine. Access t o supply connec- t ion terminals i n machine may be gained by door i n r i g h t hand side panel. Use a f l ex ib l e 4 core primary cable for portable machines and clamp cable to ensure that there i s no s t r a in on cable connections. The earth (or grourd) connection (green/ yellow) m u s t be securely fastened t o the 'earth' terminal on the machine adjacent to the.supply connection terminals.

CAUTION Before inser t ing primary cable plug i n mains supply socket, ensure that switch on both p l u g socket and welding machine i s i n 'OFF' position.

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c ) Connection of Cables/Hoses, e tc . With u n i t switched 'OFF' connect control cable ( 6 pin plug) from power source t o wire feeder. Connect gas hose from wire feeder to gas regulator/flswmeter, ensuring all connections are tightened f i r m l y . If C 0 2 Gas Shield i s being used, plug heater into 110 volt socket a t rear of u n i t . Next i n se r t gun cable into socket of wire feeder output guide and r e t a in i n place w i t h s e t screw provided. Set screw should not be tightened so as to prevent gun cable from swivelling. Connect "Gas Hose" and "Gun Switch" leads to respective sockets.

d ) WELDING CABLES.

A l l G,M.A. welding i s done w i t h electrode wire connected t o "positive" pole commonly known as D.C. reverse polarity (D.C.R.P.) therefore, connect the short jumper lead from socket on machine t o terminal. lug on gun cable. The work lead ("negative") should be .plugged in to the ' ' - I 1 socket on the

. machine. The plugs of t h e welding cables must be f u l l y inserted i n t h e sockets, t o prevent accidental disconnection. To avoid e r ror , welding s h o u l d not be attempted u n t i l all. connections have been securedc The wire feeder may be ins ta l led remote from. the power source, i n which case, extension lead sets com- pr is ing power cable, gas hose and control cable(four core) are required i n accordance w i t h the desired length.Standard length available from stock i s 9 metres.

3 ) WIRE FEEDER AND GUN CABLE.

F i t a spool of wire to the wire feeder (see notes i n "Wire Feeder Instruction Manual"). Tighten the "brake" screw u n t i l a sl ight braking effect i s f e l t when turning the wire spool by hand t o prevent ''over-run" when wire feed stops. The wire dr ive ro l l s and inlet wire guide should be selected i n accord- ance w i t h t h e diameter and type of wire being used. Refer t o current wire feeder manual for correct selection of wire feed r o l l s and input guides.

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

The gun cable and gun are normally delivered w i t h t h e contact t i p and l iner spr ing for wire s ize nominaked, b u t check tha t both are correct size for wise being used.

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EELDING OPERATION INSTRUCTIONS

8. SINGLE FUNCTION CHECK

U n i t is now ready f o r operation, b u t pr ior t o commencing weld- ing, the following "functions check" i s recommended, switch on power source and check a i r flow. See t h a t a l l welding lead plugs are inserted i n the correct polarity sockets - electrode "posit ive", work "negative". Check a l l welding connections and plugs for t ightness particularly ''work" clamp.

Next ensure tha t a l l cont ro l cab les and gas hoses are securely connected and tha t Gas Heater ( f o r CO2 only) i s plugged i n t o socket a t rear of power source. Switch on wire feeder, indic- a tor l igh t should now show "Power On". Open Gas cylinder f u l l y and check contents gauge for adequate gas supply.

Press "Gas Purge" switch and s e t gas flow i n accordance w i t h welding requirements, a t t h e same time check that gas flow i s adequate from gun nozzle. Set ''wire speed" control t o desired wire speed, Press "wire inch'' switch and check wire feed for correct pressure on drive rolls . Pressure should be s u f - f i c i en t to prevent any "s l ip" when feeding through gun and cable.

Next, close gun switch momentarily for wire feed, gas f l o w and welding power check. Set the voltage selector switches i n accordance w i t h required voltage (see welding table),unit i s now ready for welding.

9. SETTING OF WELDING CURREXlT AND VOLTAGE

Welding current i s determined automatically by the 'wire speed'. The electrode wire is fed at the pre-selected speed by drive r o l l s through the gun cable to the arc a t a constant speed, unchanged except when reset by the 'wire speed' control. The higher the w i r e speed, the higher the welding current.

The output voltage of the power source when the gun switch i s closed, i s divided into a number of steps by coarse selector and fine selector switches. The 'course' selector switch i s a combined high/low range ON/OFF switch working i n conjunction w i t h a "fine" selector switch giving 30 voltage steps.

The foll.awing sequence of weld se t t ing i s recommended:-

a ) Consu l t typical weld set t ing char t . b ) Select welding current most suited t o the application by following the settings of w i r e speed and voltage shown on the set t ing char t . To "tune" each weld set t ing, adjust wire speed on ly c ) I f voltage is too Low for the application, wire "stubbing" w i l l occur , par t icu lar ly a t s ta r t of weld and weld contour w i l l be very convex. If the voltage i s too high, metal transfer w i l l be e r r a t i c w i t h excess spatter. d ) With welding current and voltage matched the result w i l l be an optim.um tuned welding condition w i t h a smooth spatter-free arc.

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10. SAFETY DEVICES

I n t h e event sf the power source becoming overheated the ther- mostats on the diode heat s i n k s w i l l operate preventing further welding. The thermostats will automatically reset and w i t h the cooling fan operating t h i s w i l l take approximately 10 minutes. A check should be made to ascer ta in t h e reason for the over- heating such as €an not operating or a i r flow res t r ic ted . Fuses provided for a l l c i r cu i t s a r e a s follows and are indicated on the front panel:-

Fuse E l - 3 amps (Delayed action) Fuse E2 - 3 amps ( Fuse E3 - 5 amps ( Fuse E4 - 5 amps (

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11, MAINTENANCE

a ) Power Source Apart from the fan the rectifier has no rotary components. To achieve complete dissipation of heat from the active components, t he r ec t i f i e r should be thoroughly blown off w i t h ary compressed a i r a f t e r 6 rmnths' operation. Cleaning should be carried o u t a t shor te r in te rva ls i f d u s t accumulation i s considerable.

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

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

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

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

Trouble-free operation depends t o a large extent on the good condition and cleanliness of t h e i n n e r wire l iner (See I n s t r u c - t ions on Gun Cables).

1 2 . WELDING OPERATION

Never observe the arc w i t h unprotected eyes. It is of import- ance that the welder wear protective clothing providing suffic- i en t safety.

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13. STOPPAGES AND T H E I R ELIMINATION

The machine should be checked only by a fully ski l led e lectr ic ian. I S the u n i t stops working, f irst determine whether stoppages are in i t i a t ed by the mains (for instance, b u r n t fuse) or by the supply cable (loose connection, cable break) or by t h e u n i t proper.

If the three terminals L1, L2 and L3 on t h e board are correct ly connected t o t h e m.ains t h e cause of the stoppage must be sought i n

primary terminal (voltmeter reading) the u n i t i t s e l f .

The wiring diagram an the next pages will f a c i l i t a t e t h e location af the defect.

WELDING DATA TYPICAL VALUES

Shielding Gas i s welding Grade C 0 2 used w i t h a Gas Preheater. Contact Tip 1.5m inside of Gas Nozzle., Wire "Stick O u t t 1 6 -- 9mmup t o 200 amps. 9 - 12mmover 200 amps. These Tables are a guide only for. i n i t i a l machine se t t i ng and finer adjustments may be necessary t o achieve optimum welding charac te r i s t ics for t h e application. Recommended machine se t t i ng method i s t o set Voltage Switches, Inductance and Gas Flow as per Table then adjust wire speed t o obtain recamended current. TYPICAL WELD SETTINGS, CP.25 - GAS : C 0 2 (10 Eitres/min)

0.9mm MILD STEEL WIRE Wire Speed Volts Amps.

L . 9 (metres/min) 18 .O 50 3.0 I' 17.0 75 3.7 'I 18.0 85 4.1 'I 99.Q LQO 5.0 I t 19.5 120 6.8 It 21.5 150 9.2 23.0 175

12.1 II I1 25.0 200 L6.8 I t 11 32.0 250

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1,.2fnm M I L D STEEL WIRE Wire Speed Volts Amps.

2.5 (metres/min) 18.0 100 2.9 18.5 130

3.3 19.0 140 4.0 I I 20.0 160 5.3 23.0 200 6.4 23.0 230 8 .2 11 11 28.0 250

10.8 11 I t 32.0 280

13.4 32.0 300

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

DRAWING NO. CP25-03 ISSUE NO. 4

- ITEM NO.

l 2

3

4

5 6

7

8

9

10 11

1 2 13 1 4

15

L6 17

L8

L9 20

21 22

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16

- PART NO.

C P 3 5 - l 1

CP25-34

CP15- l4

CP24-0/4

CP24-0/5

CP25-42

CP2-0/9

CP3-62

CP2-0/13

CP3-0/30

CP3-0/35

CP3-0/47 w1-22

w1-23 ZP25-0/18 2P25-03/16

2P2-0/31 c1P25-19

2P35- l2 Y35-13

2P35-14/1

JP35-14/2

3P3 5- 15

UN44

2P35-17

W16

2P25-26

lP35-18

:p35-19

L0029F 'C262

CC262N

L030010

1C40-20/3

:P35-0/37 :P35-0/38

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DESCRIPTION

Frame Assembly Transformer Assembly Inductance , Assembly Fan Blade Fan Motor Rectifier Assembly Gas Heater P l u g

R e c t i f i e r P r o t e c t i o n Assembly Welding Contac tor Ammeter Shunt Ammeter 0-400 Amps. Vol tmeter 0 - 60 V o l t

I n d i c a t o r L i g h t Fuse Holders F i n e S e l e c t o r S w i t c h Coarse S e l e c t o r S w i t c h C o n t r o l P l u g F r o n t P a n e l Back P a n e l Top Cover L e f t Hand S i d e Cover Right Hand Side Cover Zontac tor and Swi tch Baffle P la t e Type No. S e r i a l No. Plate Terminal Assembly I u t p u t T e r m i n a l s Fransformer Suppor t P i e Bar

?an Mounting Bracket 3ye Nut ;as O u t l e t F i t t i n g J u t f o r Above 3/4"W x 3" Hex. HD. Set Screw. 3 a k e l i t e Insulators Loom Assembly ;as Hose

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