CP109-0 Weldmatic 215S Manual - Welding Industries of Australia
Contents
1. P 6 Fi Positive Wire Connection AA N P Fig 4 Negative Wire Connection haa P 8 Pig 5 cesta Good Weld DN aaen oeer eei oe aaea eae E ah P 10 PID anek B d Weld enan RS A xila da kr b k N ba kene ie AE P 10 Fig 7 Gun Position see eee P 10 F Q Geter cae CP109 10 Control Board eee P 14 EIR er CP109 0 Circuit Diagram eee n P 15 Fig 10 Power Source Assembly ee P 17 Fig 11 Wire Drive Assembly eee P 18 Fig 12 Gun Cable Assembly inmek P 19 WELDMATIC 2155 MANUAL Page 3 1 INTRODUCTION Gas Metal Arc Welding G M A W is a welding process where a consumable wire is fed by motor driven drive rollers 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 shielded by gas flow from the gun or in the case of self shielded wires by gases generated by the wire core By selection of the correct wire composition diameter and shielding gas G M A W can be used for applications ranging from sheetmetal to heavy plate and metals ranging from carbon steel to aluminium alloys The WELDMATIC 215S has been designed to be used with consumable wires in the range from 0 6mm to 1 2mm diameter The smaller wire size2. Motor amp Gearbox TAWA AAA KAA VF anaon Euro Gun Adaptor inc Guide amp Gas Connector O O aaaea WIFO01 3 n xx mz 2 Roll Feed Plate Pressure Arm Complete Pressure Roll 30mm Diameter Pressure Screw Complete Insulation Board Insulation Washer Feed Roll 30mm 0 8 1 0mm Solid Wire Positioning Screw Main Gear Inlet Guide Inlet Guide Tube Feed Roll 0 6 0 8mm Solid Wire Feed Roll 0 9 1 2mm Solid Wire Feed Roll 1 0 1 2mm Solid Wire Feed Roll 1 2 1 6mm Solid Wire Feed Roll 1 0 1 2mm Aluminium Wire Feed Roll 1 0 1 2mm Flux Cored Wire Feed Roll 1 2 1 6mm Flux Cored Wire O Oe PANEL FIGURE 11 CP109 7 TWO ROLL DRIVE ASSEMBLY WELDMATIC 215S MANUAL 13 PARTS LIST BEXT2 4E210AE GUN ASSEMBLY ITEM Z DESCRIPTION PART 1 Nozz e BE4392 2 Contact tip 0 6mm BE7497 Contact tip 0 8mm BE7488 Contact tip 0 9mm BE7489 Contact tip 1 2mm BE7490 3 blead asa faae BE4335 4 CADA linn tethers ct BE4323R 5 Nut Insulator BE4780 6 Insulator BE1370117 7 Body Tube BE1370116 8 Handle Kit BE1780006 9 TIGGE i ika kabe BE5662 10 Screw Kit BE1880004 14 Cable 3m BE8681TE Page 19 DESCRIPTION PART End Fitting BE4E213B Cone Nut BE4305 Terminal
3. BE2660001 Cilamp BE1520008 Strain Relief BE2520017 Bushing BE1470007 Strain Relief rigid BE1880135 SCTEW EE BE2280002 Insulated Link H2072 Nutara mie pea Teze yan BE4816 Euro Block BE5060 O Ring BE4421 Liner 0 9 1 2mrm BE43110 To replace liner Disconnect gun cable assembly from the Euro adaptor on the machine case remove nozzle 1 and head 3 Withdraw old liner from the wire feeder 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 FIGURE 12 BEXT2 4E210AE 200 AMP GUN CABLE ASSEMBLY Page 20 WELDMATIC 2155 MANUAL 14 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 WTIA Technical Note TN7 98 also provides a comprehensive guide to safe practices in welding EYE PROTE
4. no wirefeed when gun switch is closed but After cooling if problem still persists check rectifier thermostat and transformer thermostat for open circuit Replace if faulty 1 power light is on Check all connections to CP109 10 control board in power source 2 overload light is on 3 fans are running Power source has no output and no wirefeed when gun switch is Gun switch circuit incomplete Check gun switch for continuity with ohm meter when switch is pressed Replace if faulty closed but Gun switch circuit incomplete Check the 2 pin receptacles in euro 1 power light is on 2 overload light is off adaptor are making contact with the 2 pins from the gun cable Check all connections to CP109 10 control board in power source Replace CP109 10 control board 3 fans are running Power source has live output all Check triac in rectifier assembly of power source Switch off mains the time when mains power is power and disconnect yellow wire from gate terminal of triac applied and gun switch is off Switch on mains power and if output is still live replace triac Replace CP109 10 control board Power source has low weld Check welding circuit is making good electrical connection output Check all cable connections in power source for hot spots Power source has no weld output Check all cable connections to coarse and fine switches variation when coarse and fine Check co
5. LAST an otek r n A P 6 DOL een a k o ank Connection To Electrical Mains Power Supply P 6 BD a Piedad Fitting The Gas Bottle P 7 a Bt Nene Renee tora Fitting The Gun Cable eee eee P 7 LE DD Fitting The Consumable Wire P 7 DES DAN Feeding The Consumable Wire P 7 BO tains Output Voltage Polarity Selection P 8 Sec 6 Normal Welding Sequence see eee P 9 so NENN Weld e Ta sna pay 106k tt nna ne Ke r dee nakan a 0e P 9 AAA Weld Say AA WWW P 9 Sec T sneer Basic Welding Information EEEELU P 9 rav N Choice Of Shielding Gas eee P 9 YAA Dy Shielding Gas Flow Rate eee P 9 T NISWA Establishing A Weld Setting P 9 CO ese ee G n POSTION k s ides K leka kerkene aak ikak P 10 DOO O A eal General Maintenance eee ee e P 11 DOC Osteen Trouble Shooting sese eee e e P 12 Sec 10 Service Information eee e e P 14 eT R eee ee ee ee Parts List Power Source Assembiv P 16 Sec T Parts List Wire Drive Assemb iy P 18 SETI ui Parts List Gun Cable Assembly P 19 S60 Mirenen Safe Practices segnor KWLA da urd Ran kb aye Serek P 20 FIGURES PAGS 15en Power Source Control Locations P 5 PIH ae Connection of Supply Cable
6. order to obtain the most satisfactory welding results from the G M A W process the wirefeed must be smooth and constant It is therefore important to observe the following points E Keep the gun cable liner clear of dust and swarf build up When replacement becomes necessary fit only the correct liner to suit the gun cable model See page 19 The build up of dust in a cable liner can be minimised by regular purging of the liner with dry compressed air This may be conveniently done each time the wire spool is replaced B Replace the welding tip as it becomes worn B Keep the wire drive mechanism clean Periodically check the drive rollers for wear and for free rotation Check that the consumable wire spool holder rotates smoothly and that the braking action is not excessive This also may be conveniently done each time the wire is replenished Page 12 WELDMATIC 215S MANUAL 9 TROUBLE SHOOTING REMEDY Power source has no power ie Turn on mains supply switch 1 power light is off Check mains voltage fuses or circuit breaker 2 fans are not running Check all primary connections in power source and in primary plug Power source has no output but Check all connections to CP109 10 control board in power source Replace CP109 10 control board 1 power light is off 2 fans are running Power source has no output and Power source overheated Allow thermostats to cool with fans on
7. 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 f 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 n Combustibles including building construction are within 10 metres R Combustibles are further than 10 metres but can be ignited by sparks B Openings concealed or visible in floors or walls within 10 metres may expose combustibles to sparks E Combustibles adj
8. 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 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 7 3 ESTABLISHING A WELD SETTING Once the consumable wire type wire size and shielding gas have been chosen the two variables which are adjusted in order to obtain a stable arc are B Wirefeed speed B Welding arc voltage Page 10 WELDMATIC 2155 MANUAL The wirefeed rate determines the welding current increasing the feed rate increases the current and decreasing it decreases current The selected wirefeed rate must be matched with sufficient arc voltage an increase of wirefeed rate requires an increase of arc voltage If the voltage is too low the wire will stub and stutter and there will not be a steady arc If the voltage is too high the arc will be long with the metal transfer within the arc occurring as a series of large droplets IMPORTANT Do not operate the Voltage Control switches during welding The welding current should be chosen to suit the thickness of the metal to be welded It is important to chec
9. 215S MANUAL Page 5 4 POWER SOURCE CONTROLS 4 WIRE SPEED CONTROL 5 SPOT TIME CONTROL 6 INTERVAL CONTROL 7 OVERLOAD INDICATOR 1 POWER ON INDICATOR G3 FINE VOLTAGE CONTROL 2 COARSE VOLTAGE CONTROL FIGURE 1 POWER SOURCE CONTROL 1 POWER ON INDICATOR This is illuminated when electrical mains power is connected to the welding power source 2 COARSE VOLTAGE CONTROL This switch provides Coarse adjustment of the Output Welding Voltage over three ranges 3 FINE VOLTAGE CONTROL This switch provides Fine adjustment of the Output Welding Voltage over three ranges 4 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 5 SPOT TIME CONTROL When operating the machine in Spot Weld mode this control will vary the spot weld time Rotating the dial in a clockwise direction will increase the spot weld time in the range 0 4 3 0 seconds If the Spot Weld mode is not required this feature may be turned off by rotating the contro anti clockwise until it clicks into the minimum position 6 INTERVAL CONTROL When operating the machine in Cycle Arc mode this control sets the period between welds The spot time control sets the welding period Rotating the dial in a clockwise direction will increase the interval time in the range 0 4 1 8 seconds If the Cycle Ar
10. CTION 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 TO EE LA Ui 12 13 100 150 WA ence eer b VO enekeni 12 13 150 200 TSR h LO Sa Ba BASE 11 12 12 13 200 300 13515an olek 115i un na E 12 13 300 400 WA ia Dy ASA 14 400 500 J n T Tai Winged ee skape 14 500 AE WAA n asas AA a dak 1 cela x azi 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 spa
11. Not Shown SCR Module Not Shown Heatsink Not Shown Base Assembly Castor Wheel 2 Front Panel Back Panel Centre Panel Assembly Baffle Panel Side Cover Fixed Lower Not Shown Door Hinged Not Shown Top Cover Slam Action Latch On Door Not Shown Side Cover Not Shown Rubber Tyre Wheel 2 Ratchet Cap 2 Loom Assembly Low Voltage Not Shown External Polarity Change Lead Loom Assembly Transformer Not Shown Loom Assembly High Voitage Not Shown Socket Dinsel 25mm 2 Terminal Block 2 position Cooling Fan 2 Gas Valve 24V DC Gas Valve Hose Tail 2 O Clip 2 20A Flex amp 15A Plug Rod Hinge Not Shown Potentiometer Knob Small 2 Potentiometer Knob Large Black Oxy Single Hose Steel Chain 650mm Rubber Grommet Handle Assy Plastic Cover Switch 2 Cable Clamp Busbar Inductance Busbar inductance to Output ve Busbar Rectifier ve to Inductance Busbar Rectifier ve to Output ve Male Insulating Bush For Flex Cord Not Shown Female insulating Bush For Flex Cord Not Shown CP109 0 Owner s Manual Not Shown WELDMATIC 215S MANUAL Page 17 S sa Sa eer ee G gt N FIGURE 10 WELDMATIC 215S POWER SOURCE ASSEMBLY Page 18 WELDMATIC 215S MANUAL 12 PARTS LIST CP109 7 MOTOR TWO ROLL DRIVE amp EURO ADAPTOR ASSEMBLY ITEM PARTH iii aki DESCRIPTION Taa Vote WF001 1
12. S VALVE WIREFEED MOTOR VE FIGURE 8 CP109 10 CONTROL BOARD Page 15 l lt 5 Z lt 2 N lO N Q lt O al TI E J UUUOjSUB1J 18 S0U18U L lt g 3 2 2 td Zd aanpBay J0J0 Jeyoay 10 60UUJ3U L d Menno TE eE a uams ung aise BASOJ 100W Zd MSA 1e16otuJau J daa4 HIM gt ang NX AWA SYO 9d AAPA SED lt vo 89d 19p33JaJIM O1 60ld9 Sd bid 3 Zid Nid Jopnpu BuipiaAA i py 6 28 E 9 GMO KO ansad Umoja L asyvoo srt 18UJJ0 SU 8J1 Buin FIGURE 9 CP109 0 CIRCUIT DIAGRAM WELDMATIC 215S MANUAL Page 16 11 PARTS LIST WELDMATIC 215S POWER SOURCE ITEM PART Z n ie et he CP109 10N DAA aa E N CP109 5L Includes E cs Dini N ee CP104 16 2 AA N ATA cP109 6 L AMA UNA es ae CP109 8 Includes Nees ct Th eee ed CP106 0 1 LS L k AAA SAANA KAA LA EA WAWA SD iat NE EK WE Me CP102 51 2 ES eG aa ER DAYE CP109 32 WANA KASI MANDA SAWA Zabi CP43 23 me Includes Bla CP42 24 6 DESCRIPTION PCB Assy Wirefeed Weld Transformer Assy inc Overload amp Wire Loom Thermal Overload Inductance Assembly Rectifier Assembly Rectifier with Thermal overload Thermal Overload
13. WELDING INDUSTRIES OF AUSTRALIA A DIVISION OF WELDING INDUSTRIES LTD ABN 18 004 547 111 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 info weldingindusitries com au OWNERS MANUAL WELDMATIC 215S MODEL NO CP109 0 REV B 11 2000 QUALITY WELDING PRODUCTS SYSTEMS AND SERVICE Puraj Page 2 WELDMATIC 215S 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 CONTENTS T el Pp re Ene Introduction senn ag edna P 3 SEC 2i FRCS ya ce oera Wr P 3 AST gt e eee ne a Specifications r rr P 4 Sec 4 Power Source COonrO S s eee P 5 Sec 5
14. acent 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 i
15. arse and fine switches Switches are operated Replace if faulty Mains fuses blow or circuit Check welding transformer for a primary fault to earth breaker trips instantly when Replace if faulty mains voltage is applied Check fan in power source for short circuit or fault to earth Replace if faulty Mains fuses blow or circuit Check welding transformer for shorted turns Replace if faulty Check rectifier for shorted diodes Replace if faulty breaker trips instantly when gun switch is closed Mains fuses blow or circuit breaker trips when welding Check that the recommended fuse or circuit breaker rating has been used Consider upgrading to larger fuse or circuit breaker amp wiring WELDMATIC 215S MANUAL Page 13 TROUBLE SHOOTING cont UNSATISFACTORY WELDING PERFORMANCE AND RESULTS ______REMEDY_ __ Erratic arc characteristics Check gun liner for build up of dirt or blockage Replace if dirty Check if wire is slipping on roller assembly Replace feed roll if worn_ Check that gun liner is not too short and is fitted correctly Refer to page 19 for fitting instructions Check correct polarity has been selected for work and weld cables Refer to page 8 Check shielding gas is correct for the consumable in use Check welding circuit is making good electrical connection Check all connections in power source and wirefeeder for hot spots Check gas solenoid Replac
16. c mode is not required this feature may be turned off by rotating both controls fully anti clockwise 7 OVERLOAD INDICATOR This is illuminated when the welding load exceeds the operating duty cycle In this event the machine will not deliver welding current until the machine has cooled sufficiently The over temperature thermostats will reset automatically do not switch the machine off as the cooling fan will assist the resetting of the thermostats Page 6 WELDMATIC 2155 MANUAL 5 INSTALLATION 5 1 CONNECTION TO ELECTRICAL MAINS POWER SUPPLY NOTE All electrical work shall only be undertaken by a qualified electrician The WELDMATIC 2155S is factory fitted with a 3 metre 3 core 50 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 machine The effective primary current for a Weldmatic 215S is 16 Amps The minimum recommended circuit breaker rating for a Weldmatic 215S is 20 Amps Note The tripping time of a typical 20A circuit breaker may limit the duty cycle available from the Weldmatic 215S A higher rated circuit breaker can be s
17. ce 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 2155 MANUAL Page 21 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
18. e See Figure 4 below WORK LEAD FIGURE 4 NEGATIVE WIRE WELDMATIC 2155 MANUAL Page 9 6 NORMAL WELDING SEQUENCE 6 1 WELD START Closing the welding gun switch initiates this sequence of events The gas valve is energised gas flow commences E The power source triac function is initiated Welding voltage is applied between the work piece and the consumable wire The wire drive motor is energised Wirefeed commences and the arc is established 6 2 WELD END Releasing the gun switch initiates this sequence of events B The wire drive motor is de energised and is dynamically braked to a stop B The power source triac function is de energised E The gas valve is de energised and the flow of shielding gas ceases 7 BASIC WELDING INFORMATION 7 1 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 2158 are Mild Steel Argon 5 to 25 Carbon Dioxide B Aluminium 2eemmeme Argon u Stainless Steel Argon 1 to 2 Oxygen Consult your gas supplier if more specific information is required 7 2 SHIELDING GAS FLOW RATE In G M A welding one of the functions of the shielding gas is to protect the molten weld pool from the effects of oxygen in the atmosphere Without this protection the
19. e if faulty Check that the correct gas flow rate has been set Check for leaks in gas hose Replace if leaking Check for leaks in gun cable eg o rings Replace if leaking Check nozzle is firmly attached to gun and that no air is being caused by poor wirefeed Constant poor arc characteristics Porosity in weld caused by lack of shielding gas drawn in Page 14 WELDMATIC 2155 MANUAL 10 SERVICE INFORMATION CP109 10 CONTROL BOARD The CP109 10 Control board provides the following functions B Welding transformer ON OFF control Wirefeed motor ON OFF control Speed control of the wirefeed motor E Braking of the wirefeed motor at end of weld Spot weld timer Interval timer Gas solenoid ON OFF control Triac ON OFF control phase selected to minimise transformer inrush current Triac protection by output short circuit detection Connections to the board are detailed in the drawing below The circuit is factory adjusted to provide a maximum drive roller speed of 160 rpm MAXIMUM SPEED CALIBRATION UO E at it Uma ini 9285892955 cio XAA aps D Qina 2 ne Dba d 2 p4 w ACTIVE 240VAC THERMOSTAT g NEUTRAL 240VAC THERMOSTAT OUTPUT TERMINAL VE DANGER 240V SUE eran Tal R32 ct OUTPUT TERMINAL VE GUN ERE SECONDARY TRANSFORMER GUN SWITCH SECONDARY TRANSFORMER GAS VALVE WIREFEED MOTOR VE GA
20. elected 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 machine supply terminals is gained by removing the power source left hand side panel Power source viewed from front Pass the cable through the bush fitted to the machine back panel The cables are terminated at the terminal block as shown in Figure 2 Tighten the cable clamp leaving just sufficient slack in the cable so that the terminated wires are not in tension BACK CABLE BLUE BROWN TERMINAL PANEL WIRE BLOCK 3 CORE POWER CABLE PLASTIC GREEN BUSH CONNECTION YELLOW WIRE FIGURE 2 CONNECTION OF SUPPLY FLEXIBLE CABLE WELDMATIC 2155 MANUAL Page 7 5 2 FITTING THE GAS BOTTLE Depending on configuration of the cylinder to be used the gas flowmeter regulator may be fitted directly to the cylinder or in conjunction with an elbow fitting DO NOT apply any grease to these joints and tighten the nuts securely Fit the end of the gas inlet hose from the back of the machine to the connector supplied with the flow regulator and secure with the clamp also supplied 5 3 FITTING THE GUN CABLE The BERNARD BEXT2 4E210AE gun cable is equipped with a Euro wirefeeder connector which incorporates all required connec
21. k that the deposited weld provides sufficient strength to suit the application A good weld will have the characteristics illustrated in Figure 5 The weld has penetrated into the parent metal fusing the root of the joint where the two plates meet and the weld blends smoothly into the side walls A bad weld is shown in Figure 6 The weld has not penetrated the joint root and there is poor side wall fusion This lack of fusion would normally be corrected by increasing the arc voltage or by increasing both wirefeed rate and arc voltage to achieve a higher current weld setting FIGURE 5 GOOD WELD FIGURE 6 BAD WELD 7 4 GUN POSITION For down hana fillet welding the gun is normally positioned as shown in Figure 7 below with the nozzle end pointing in the direction of travel FIGURE 7 GUN POSITION WELDMATIC 215S MANUAL Page 11 8 GENERAL MAINTENANCE Before removing the machine cover ENSURE that the unit is disconnected from the mains power supply When the unit is energised LETHAL VOLTAGES are present on the electrical components enclosed i DUST Care should be taken to prevent excessive build up of dust and dirt within the welding power source It is recommended that at regular intervals according to the prevailing conditions the machine covers and enclosed wirefeeder covers be removed and any accumulated dust be removed by the use of dry low pressure compressed air or a vacuum cleaner WIREFEED In
22. nsulated 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
23. s 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 such as AUSTMIG ES6 is used with a shielding gas of Argon mixed with 5 25 Carbon Dioxide Alternatively Flux cored consumables 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 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 CP109 0 package contains R WELDMATIC 215S Power source l BEXT2 4E210AE BERNARD Gun cable 3 metre Euro connector E WGAC24 Regulator and Flow gauge Argon This Owners Manual Page 4 WELDMATIC 2155 MANUAL 3 SPECIFICATIONS Manufactured to Australian standard AS1966 1 1985 Rated to ISO IEC 60974 1 10 minute duty cycle WELDING INDUSTRIES of AUSTRALIA Weldmatic 275s Made in Australia RATED TO ISO IEC 60974 1 Op gt Jaje a pa e eq o LE CLASS INS H COOLING AF Under ISO IEC 60974 1 duty cycle is defined as the ratio of arcing time to an operating time of 10 minutes expressed as a percentage WELDMATIC
24. se 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 11 of this manual Return the pressure arm to the closed position and adjust the pressure screw to provide sufficient clamping of the drive rolls drive to achieve constant wirefeed Do not over tighten Page 8 WELDMATIC 215S MANUAL 5 6 OUTPUT VOLTAGE POLARITY SELECTION The design of the WELDMATIC 215S allows external selection of the output voltage polarity positive wire or negative wire 5 6 1 POSITIVE WIRE Most solid wire G M A W is carried out with the work piece Negative and the welding consumable wire Positive To set the machine for this condition insert the WORK lead plug into the output socket on the front of the power source Insert inter connecting WELD lead plug into the output socket on the front of the power source See Figure 3 below 5 6 2 NEGATIVE WIRE Some self shielded flux cored consumables are intended to be operated with the work piece Positive and the consumable wire Negative Refer to the manufacturers data for the particular consumable to be used To set the machine for this condition insert the WORK lead plug into the output socket on the front of the power source Insert inter connecting WELD lead plug into the output socket on the front of the power sourc
25. tion points to the gun cable for welding current shielding gas and gun switch control To attach the gun cable to the wirefeeding mechanism engage the mating parts of the male and female Euro connectors then rotate the locking ring clockwise to firmly secure the connection 5 4 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 5 5 FEEDING THE CONSUMABLE WIRE With reference to Figure 11 release the pressure screw 6 and rotate the pressure arm 4 to the open position The end of the welding wire can now be passed through the inlet guide 11 over the bottom driven roller 9 and into the output wire guide tube Check that the drive roller groove is correct for the wire in u
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