WELDING INDUSTRIES Weldmatic 150 Manuale utente
WELDING INDUSTRIES OF AUSTRALIA
a division of Welding Industries Ltd
ABN 18 004 547 111
Telephone 1300 300 884
Facsimile 1300 301 884
Email: [email protected]
www.welding.com.au
Weldmatic 150
[internal wirefeeder]
Operators Manual
Weldmatic 150 MIG welder
Model No. CP115-0, Iss E
02/05
CP115-40 Rev E
Weldmatic 150 Operators Manual
2 Model No. CP115-0, Iss E 02/05 Quality, Reliability, Performance
Contents
Section General Information Page
Safe Practices 3
1 Introduction 5
2 Receiving 5
3 Specifications 6
4 Controls 7
5 Installation 8
6 Normal Welding Sequence 10
7 Basic Welding Information 10
8 General Maintenance 14
9 Trouble Shooting 15
10 Service Information 16
11 Assembly and Parts Lists
11.1 Power Source 18
11.2 Wirefeed assembly 20
11.3 Gun and Cable Assembly 21
12 Warranty information 22
Weldmatic 150Operators Manual
Model No. CP115-0, Iss E 02/05 3
Quality, Reliability, Performance
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.
Australian Standard AS1674.2 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 11 10 10 12-13
150-200 12 10-11 11-12 12-13
200-300 13 11 12-13 12-13
300-400 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 light-
weight 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.
Read First
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 ordering spare parts, please quote
the model and serial number of the
power source 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, please read the Safe Practices
section of this manual. This will help to
avoid possible injury due to misuse or
improper welding applications.
Plastic Handles on Power Source
Please note that the handles fitted to
the Weldmatic 150 power source are
intended for carrying the equipment by
hand only.
DO NOT use these handles for suspending
or mounting the power source in any
other manner.
Weldmatic 150 Operators Manual
4 Model No. CP115-0, Iss E 02/05 Quality, Reliability, Performance
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.
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.1674-2. 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.1674-2. 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
equipment is correctly connected and earthed.
If unsure have the equipment 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.
Weldmatic 150Operators Manual
Model No. CP115-0, Iss E 02/05 5
Quality, Reliability, Performance
1 Introduction
Gas Metal Arc Welding (G.M.A.W.) is an arc
welding process where a consumable wire is
fed by motor driven feed rolls to a welding
gun, and where 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 shielded by gas flow from the gun, or
in the case of “self shielded” wires, by gases
generated by the wire core.
The process is very versatile in that by selection
of the correct wire composition, diameter and
shielding gas, it can be used for applications
ranging from sheet-metal to heavy plate, and
metals ranging from carbon steel to aluminium
alloys.
The Weldmatic 150 has been designed to be
used with consumable wires in the range from
0.6mm to 1.2mm diameter. The smaller wire
sizes are used when welding at lower currents,
such as sheet-metal applications. Increasing the
wire diameter permits higher welding currents
to be selected.
A common application of G.M.A.W. is for
welding Mild Steel. In this application, a Mild
Steel solid consumable wire such as AUSTMIG
ES6 is used with a shielding gas of Carbon
Dioxide, or Argon mixed with Carbon Dioxide.
Alternatively, Flux-cored consumable wires are
available in both gas shielded, and ‘gasless’ self
shielding types.
Stainless steel and Aluminium can be welded
with G.M.A.W. using the correct consumable
wire and shielding gas.
The Weldmatic 150 wirefeeder has been
designed to feed a range of hard, soft, and
flux-cored wires for the G.M.A.W. process.
A compact motor with integral gear box is
coupled to a two roll drive assembly forming
the basic component of the wirefeeder. The
motor is controlled by an electronic speed
control which provides speed regulation.
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 CP115-0 package contains;
• Weldmatic CP115-0
• 3m Bernard gun and cable assembly
• 3m work lead
• Argon/mixed gas regulator
• (This) Operating Manual CP115-40.
Weldmatic 150 Operators Manual
6 Model No. CP115-0, Iss E 02/05 Quality, Reliability, Performance
3 Specifications
Manufactured to Australian Standard
AS1966.1. Rated to ISO 60974-1.
Primary Voltage
240 Vac, 50/60 Hz
Rated Primary Current
12 Amps
Maximum Primary Current
28 Amps
Recommended Generator kVA
6.7 kVA
Rated Output @ 40oC
Duty cycle based on 5 minute cycle time
135 Amp, 20.8 V, 25% duty
67 Amp, 18 V, 100% duty
Welding Current
35 - 150 Amps
Open Circuit Voltage
19 - 40 V
Shipping weight
38 kg
Mains Circuit Breaker Rating
16 Amps
Supply plug
15 Amp
Fitted Supply Cable
30/0.25 Three Core, Heavy Duty PVC
Cooling
Fan cooled, air drawn in through rear grille.
Insulation
Class H, 140°C Rise
Spool Sizes
1 kg, 5 kg
Wirespeed Range
0 - 160 RPM (0 - 15 Metres per min.)
Wire Size Range
0.6mm - 0.9mm diameter (solid wire)
0.8mm - 1.2mm diameter (cored wire)
If the supply cable is damaged it must
be replaced by the manufacturer, their
service agent or a similarly qualified
person.
Weldmatic 150Operators Manual
Model No. CP115-0, Iss E 02/05 7
Quality, Reliability, Performance
Fig 1 Power Source Controls
3
4
6
5
2
1
4 Controls
1 Wire Speed Control
This control provides adjustment of the
wirefeed speed. Rotating the dial in a clockwise
direction will increase the wirefeed speed,
thereby increasing the welding current.
Refer to the Weld Setting Chart in Section
7 of this manual for information on setting
these controls to obtain the intended welding
current. This chart is also located inside the
wire-spool enclosure cover
2 Euro Gun/Cable Connector.
3 Coarse Voltage Control
This switch provides Coarse adjustment of the
output welding voltage over three ranges.
4 Fine Voltage Control
This switch provides Fine adjustment of the
output welding voltage over three ranges.
Note: Minimum welding voltage is obtained
with Coarse A and Fine 1 selected. Maximum
welding voltage is obtained with Coarse C and
Fine 3 selected.
5 Positive Welding Output Terminal
6 Negative Welding Output Terminal
Do not operate the Voltage Control
switches during welding
Weldmatic 150 Operators Manual
8 Model No. CP115-0, Iss E 02/05 Quality, Reliability, Performance
Fig 2 Positive Wire
Fig 3 Negative Wire
5 Installation
Connection to Electrical Mains Power
Supply
The Weldmatic 150 is factory fitted with a
3 metre, 3 core 30/0.25 Heavy Duty PVC mains
power supply cable with moulded 3 pin, 15
Amp, Single Phase plug.
A 15 Amp plug and socket is recognisable by
a wide Earth pin. Power Supply authorities
require that equipment fitted with a 15 Amp
plug shall ONLY be connected to a 240 Volt,
15 Amp power point. DO NOT modify the plug.
The minimum capacity of the mains wiring and
power outlet supplying a welder is selected
according to the effective primary current of
the equipment. The effective primary current
for the Weldmatic 150 is 12 Amps.
The minimum recommended mains circuit
breaker rating for a Weldmatic 150 is 16 Amps.
Note : Due to normal variations of sensitivity,
the tripping time of some 16A circuit breakers
may limit the duty cycle available from the
Weldmatic 150. A higher rated circuit breaker
can be selected, but the mains wiring capacity
must be increased to suit.
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 supply
terminals is gained by removing the power
source side panels.
The replacement cable must be fitted and
retained in the same manner as the original.
Negative Wire
Some ‘self-shielded’ flux cored consumable
wires are operated with the work piece Positive
and the consumable wire Negative. Refer
to the manufacturers data for the particular
consumable wire to be used.
To setup for this condition, connect the ‘WORK’
lead plug into the (+) output socket on the
Power Source, and the ‘WELDING’ lead from
the power source into the (-) socket, as in
Figure 3.
To work clamp
To gun cable
Replacement of the cable must be carried
out by the manufacturer, their service
agent or a similarly qualified person.
Output Voltage Polarity
The design of the Weldmatic 150 allows
selection of the output voltage polarity.
Positive Wire
G.M.A.W. with solid consumable wires is carried
out with the work piece Negative and the
welding wire Positive.
To setup for this condition, connect the ‘WORK’
lead plug into the (-) output socket on the
Power Source, and the ‘WELDING’ lead from
the power source into the (+) socket, as in
Figure 2.
To work clamp
To gun cable
Weldmatic 150Operators Manual
Model No. CP115-0, Iss E 02/05 9
Quality, Reliability, Performance
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.
Fitting the gas cylinder
Place the gas cylinder on the tray at the rear of
the optional welder trolley (if using). Retain the
cylinder with the chain provided.
Fit the gas regulator to the cylinder. DO NOT
apply grease or oil to these joints.
Fit the end of the gas inlet hose from the back
of the power source to the connector supplied
with the gas regulator, and secure with the
clamp also supplied.
Fitting The Gun and Cable Assembly
The supplied BERNARD gun/cable assembly is
equipped with a ‘Euro’ wirefeeder connector
which incorporates all required connection
points for welding current, shielding gas and
gun switch control.
To attach the gun/cable assembly 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
5 kg Spools
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 adjuster, which should
be set to prevent over run of the wire spool at
the end of a weld, without unduly loading the
wirefeed motor.
1 kg Spools
Remove the adjustor knob, spring, washer and
5 kg spool holder. Leave the 5 kg spool holder
in a safe place (ie inside the welder). Fit the 1kg
wire spool directly onto the spool axle. Fit the
washer, spring and adjustor knob and tighten
the adjustor knob fully.
Feeding the Consumable Wire
At the wirefeed assembly, release the
compression screw by swivelling it outwards.
This allows the top roller arm to spring to the
open position. The end of the welding wire
can now be passed through the inlet guide,
over the bottom driven roller, and into the
output wire guide tube. Check that the drive
roll groove is 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.
Feed roller and tip details are shown in Section
11 of this manual.
Return the top roller arm to the closed position
and adjust the compression screw to provide
sufficient clamping of the drive roll to achieve
constant wirefeed. Do not over tighten.
With the equipment energised, operate the
gun switch to feed wire through the gun cable.
Compression
screw
Top roller arm
Inlet guide
Groove size 0.9
Weldmatic 150 Operators Manual
10 Model No. CP115-0, Iss E 02/05 Quality, Reliability, Performance
7 Basic Welding Information
Choice of Shielding Gas
The choice of shielding gas is largely
determined by the consumable wire to be used.
Many proprietary shielding gas mixtures are
available.
The recommended shielding gases for use with
the Weldmatic 150 are:
• Mild Steel Argon +
5 to 25% Carbon Dioxide;
• Aluminium Argon;
• Stainless Steel Argon + 1 to 2% Oxygen.
Consult your gas supplier if more specific
information is required.
Shielding Gas Flow Rate
In G.M.A. welding, 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 10-12 litres/min. In situations where
drafts cannot be avoided, it may be necessary
to increase this rate up to 20 litres/min, and/or
to provide screening of the work area.
Weld porosity can also be caused by air
entering the gas stream through a damaged
hose, loose gas connection, or from restriction
in the nozzle, such as from excess build-up of
spatter.
When welding aluminium, particular care
must be taken with all aspects of shielding gas
delivery and workpiece preparation in order to
avoid weld porosity.
Establishing a Weld Setting
Once the consumable wire type, wire size
and shielding gas have been chosen, the two
variables that are adjusted in order to obtain a
the desired weld setting are;
• Wirefeed speed,
• Welding arc voltage.
The Weld Setting Charts in Figure 4 can be
used to preset the machine for an approximate
welding current. For each of the combinations
of voltage control switch settings, there is a
range of valid wirespeed settings.
6 Normal Welding Sequence
Weld Start
Closing the welding gun switch initiates this
sequence of events:
• The gas valve is energised and gas flow
commences;
• The power source contactor is initiated.
Welding voltage is applied between the
work piece and the consumable wire.
• The wire drive motor is energised.
• The wire touches the work piece, and the
arc is established.
Weld End
Releasing the gun switch initiates this sequence
of events:
• The wire drive motor is de-energised, and is
dynamically braked to a stop;
• The power source contactor is released.
• The gas valve is de-energised and the flow
of shielding gas ceases.
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