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CP107 Weldmatic 255S 240 Volt with W42 Feeder
Contents
1. PR AM177 Includes 15 1 0119329 lS 2278 E PRETI OPES 20 Includes CPS SOD LAY e Includes 05 RE CP27 11 2B 101 11 8 18 30 E 760 1 itor i pee HF200 1 15 MC36 56 21 V gd 51 2071 EE 1 07 23 Lo aoe 5 9 17 20 ne Pi RUP ETE 5 10 19 aii ii iore ESE WAT IO se zi EE CP102 0 18 usu WELDMATIC 2555 MANUAL DESCRIPTION PCB Assembly Wirefeed Control Base Panel Front Panel Back Panel Top Side Panel Door Panel Divider Panel Motor and 2 Roll Drive Insulating Bush 2 Motor Insulator 2 Euro Adaptor Gas Valve Hose Tail 2 O Clip 5 16 Spool Holder Assembly R Clip Loom Assembly Gas Valve Loom Assembly Fine Voltage Potentiometer 1K Loom Assembly Remote Pots Potentiometer 50K Switch
2. P 7 Fig 4 Positive Wire Connection P 8 ge Es EP RANT Negative Wire Connection 8 6 uos VWE 11 FIO Y i um 0 6 GUR POS E T TT P 11 18 9 Solid State Relay Control Board p 15 PGs Power Source Assembly S 17 EOTech CP107 0 Circuit Diagram P 18 aiio pu Prom Wirefeed Control P 19 FIG Wirefeeder P 21 FIG Va W42 0 Circuit Diagram With Lead Kit 22 e E e Gun Cable Assembly P 23 PIO T6 cen Wire Drive 22 2 2 0 4 283 Inter connecting Lead P 25 WELDMATIC 2555 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
3. CP107 30L NP 107 42 107 43 Includes 43 25 102 12 8 orea CP105 31 2 elu AM aS CP106 20 2 SERE TER CPA3 23 Includes 5 42 24 6 COPIE EROS CP107 22Y 90 1 REM 043 217 E AEREE E EE TEE CP43 24Y E CP106 25Y 44 22 42 0 3 a 30 11 53 6 Qr ei MK6 3 gt 2 1 23 escena TD D ee 107 0 2 j c 107 0 1 107 44 PA 107 45 0000 107 46 GFTI07 92 ii Iw PIC 07 53 107 54 107 47 7 39 0 1 2 CP107 39 CP107 49 Includes EM 107 49 1 Vt 1 74 HZA Lasse EEE H285 eee BZ ODE soris
4. ae E TEE dort tesis 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 tha
5. Cx cette este ies MC14 0 10 OPENPR UNDER 14 0 11 REL CADO SCGO030M Cy qM RR CAB3C50HD a CLI56P332 DU oru EN CPA2 39 ee 0 7 DESCRIPTION Rectifier Assembly Rectifier Assembly with Therma overload Solid State Relay Heatsink Assy 240V MUT PCB Assy Solid State Relay Control 0 Solid State Relay 240V 70 0000 Heatsink Dust Shield 012 Welding Transformer Assembly inc Wire Loom E Inductance Assembly inc Overload Capacitor Bank Mounting Bracket Capacitor 4 Capacitor Rail 2 DR NER Discharge Resistor 4 0 0 Base Assembly Rubber Tyre Wheel 2 levius Ratchet 2 ree Terminal Block 3 position TERR RT Fuse Holder uc Fuse 5 Amp Standard Action TS Cooling Fan 7 07 Auxiliary Transformer mn Cable Inductor End to Capacitor Neg Rail 009197 Cable Transformer to Rectifier AC 7 Cable Capacitor Pos Rail to Pos 0 Terminal 0 86 Cable Limit Ind Start to Rectifier Neg Sasa eas Cable Capacitor Pos Rail to Rectifier Pos e Cable Inductor Start to Neg O P Terminal MU Busbar Transformer to Rectifier AC Switch Coarse 0 1 Loom Assembly High Voltage Not Shown Loom Assembly Low Voltage Not Shown Cable Clamp a Male In
6. Feed Roll 1 0 1 2mm Knurled 13 IE W2 MTS sao Inlet Guide 3mm ME W2T7 2 3 tesis doin Inlet Guide 2mm oM ND 26 2 13 Inlet Guide 2mm Nylon FIGURE 16 W40 1 TWO ROLL DRIVE ASSEMBLY WELDMATIC 2555 MANUAL Page 25 AM283 INTER CONNECTING LEAD KIT ITEM PARTE DESCRIPTION AM290 1 5 2 Work Lead Includes Welding Cable 25mm2 OR E Plug a 202 CM Work Clamp 300Amp 11369 1 edu rocas Cable Lug 280 2 8 Weld Lead Includes D 25 Welding Cable 25mm2 ETE Plug 22 San 113680 Cable Lug AM283 3 8 Control Lead Includes E 856592 Cable 8 Core c 083 71 scit bets Plug 6 Pin 2 RPM Quick Connect Lug Female 6 Cr c E HATIS Insulator 2 7 280 4 8 Includes Aa c is dc Gas Hose 5mm La m I E Ru rare RENE O Clip 1 2 2 AM280 1 5
7. aratu n wirefeeder has no power but Check all connections to W42 10 circuit board wirefeeder 1 power source fan is running Check control lead for damage or broken solder joints in the 6 pin plug 2 wirefeeder power light is off Check control transformer in power source for an input voltage of 240Vac and an output voltage of 32Vac Replace if faulty Replace W42 10 circuit board in wirefeeder Power source has no output Gun switch circuit incomplete Check gun switch for continuity with when gun switch is closed but Ohm meter when switch is pressed Replace if faulty 1 power source fan is running Gun switch circuit incomplete Check the 2 pin receptacles in euro 2 wirefeeder power light is on adaptor of wirefeeder are making contact with the 2 pins from the gun 3 there is no wirefeed cable If the pins have been accidentally pushed in push and fix the pins back in place with glue or Loctite Check the two wires from wirefeed motor are connected to W42 10 circuit board Replace W42 10 circuit board Power source has no output Power source overheated Allow thermostats to cool with fan on when gun switch is closed but Check control lead for damage or broken solder joints in the 6 pin plug 1 power source fan is running After cooling check rectifier thermostat and inductance thermostat for 2 wirefeeder power
8. BEXT2 AE310AE BERNARD Gun cable metre Euro connector WGAC24 Regulator and Flowgauge Argon This Owners Manual 4 WELDMATIC 2555 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 255s Made in Australia RATED TO ISO IEC 60974 1 30A 16V 255A 27V PF 87 255A 59 100A 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 Note The machine has been shipped with a 15 Amp plug fitted to allow initial commissioning only To obtain rated output current from the WELDMATIC 2555 the 25 Amp flexible supply cable must be fitted with a 3 pin plug that is rated for at least 25 Amp and connected to a correctly installed power outlet of at least 25 Amp WELDMATIC 2555 MANUAL Page 5 4 CONTROL LOCATIONS POWER SOURCE AND WIREFEEDER POWER SOURCE WIREFEEDER FIGURE 1 CONTROL LOCATIONS POWER SOURCE AND WIREFEEDER 1 POWER ON INDICATOR This is illuminated when the wirefeeder is energised that is when electrical mains power 5 connected to the welding power source 2 COARSE VOLTAGE CONTROL This switch provides Coarse adjustment of the Output Welding Voltage over three ranges Low Medium and High 3 FINE VOLTAGE CONTROL This control provides Fine adjustment of t
9. WELD LEAD CONTROL LEAD AM283 3 8 FIGURE 17 AM283 INTER CONNECTING LEAD KIT 26 WELDMATIC 2555 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 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 MMAW MIG Pulsed MIG 0 100 PEE MNT zr ES 12 13 100 150 ipo t MU aces O EE 12 13 150 200 10 11 11 192 Se 12 13 200 300 MS T T2 E 12 13 300 400 TASES 14 14 139 400 500 500
10. any other manner CONTENTS 556 1 ITOCUCHON MSS ED RM ees SEC 566 3 505661176311675 ered Sls 4 4 Control Locations Power Source and Wirefeeder P 5 SEC A M P6 566 6 uus Normal Welding Sequence P 9 SEC Basic Welding Information P 10 8 General 12 8566 9 Trouble SHOOUNG eaa eer evita 13 566 10 Service Information Power P 15 5 11 Parts List Power P 16 Sec 12 Service Information Wirefeeder P 19 SEC 19 iot Parts List P 20 Sec 14 Sale 26 FIGURES PIG Control Locations Power Source and Wirefeeder 5 PIO Connection of Supply 06 Eg S iocos Remote Wirefeeder
11. light is on open circuit Replace if faulty 3 there is wirefeed Check all connections to CP107 10 circuit board in power source Replace CP107 10 circuit board in power source Replace W42 10 circuit board in wirefeeder Live output all the time when Check solid state relay in power source Switch off mains power and power source is switched on disconnect wires from terminals 3 amp 4 of solid state relay Switch on mains power and if output is still live replace solid state relay and gun switch is off Replace CP107 10 circuit board in power source Replace W42 10 circuit board in wirefeeder Power source has low weld Check all cable connections in power source for hot spots output Check welding circuit is making good electrical connection Wirefeeder fuse blows Check control lead for internal bridging of wires instantly when power Source Replace W42 10 circuit board in wirefeeder is Switched on Replace CP107 10 circuit board in power source Wirefeeder fuse blows after Too much drive roller pressure on wire Reduce pressure a period of welding Check gun liner for build up of dirt or blockage Replace if dirty 14 WELDMATIC 2555 MANUAL TROUBLE SHOOTING cont 0 0 n 5 n Check welding transformer for a fault to earth Replace if faulty breaker trips instantly when Check fan in power source for short circuit or fa
12. 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 255S 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 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 CP107 0 package contains WEI DMATIC 2555 Power source wA42 0 Enclosed Wirefeeder with Controls AM283 0 8 Inter connecting Lead Kit 8 metre
13. WELDING INDUSTRIES OF AUSTRALIA A DIVISION OF WELDING INDUSTRIES LTD ACN 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 weldingindustries com au OWNERS MANUAL WELDMATIC 2555 MODEL NO CP107 0 REV WITH W42 0 WIREFEEDER 09 2000 QUALITY WELDING PRODUCTS SYSTEMS AND SERVICE AA 2 WELDMATIC 2555 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 Please note that the handle fitted to the WELDMATIC W42 0 WIREFEEDER is intended for carrying the machine by hand only DO NOT use this handle for suspending or mounting the machine in
14. cket on the front of the power source See Figure 5 below WELD LEAD CONTROL LEAD uw WORK LEAD WELD LEAD CONTROL LEAD e WORK LEAD FIGURE 5 NEGATIVE WIRE WELDMATIC 255 MANUAL Page 9 6 NORMAL WELDING SEQUENCE WELD START Closing the welding gun switch initiates this sequence of events E The gas valve is energised gas flow commences The power source contactor 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 WELD END Releasing the gun switch initiates this sequence of events E The wire drive motor is de energised and is dynamically braked to a stop After a short pre set period known as the burn back time the Power source contactor function is released This period ensures that the consumable wire does not freeze in the weld pool To adjust the bum back time refer to Figure Section 12 M The gas valve is de energised and the flow of shielding gas ceases 10 WELDMATIC 2555 MANUAL 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 2555 Mild Steel Argon 5 to 25 Carb
15. east 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 B Combustibles including building construction are within 10 metres E 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
16. ed 2 Potentiometer 10K A Type Indicator Light Support Foot 4 Male Bush Female Bush Small Knob 2 Large Knob 2 Handle PCB Support 4 WELDMATIC 255 MANUAL 21 ARTS NOT SHOWN 17 LOOM ASS Y FINE VOLTAGE POTS 18 LOOM ASS Y WIREFEED REMOTE POTS d amp do dsc El S E S FIGURE 13 W42 0 WIREFEEDER WITH CONTROLS WELDMATIC 2555 MANUAL Page 22 70 68 301 599 T1dR 18 NO 5 naa lr 2 M 0 dS AH I f 33 nt8 P93 81 7 3 1 0292 4087539 390 0 INI J 11 2 PPA INI v 187 84025 8 aan ITOH LNOO uouuega quidam os 9 1 ant AS NNSD ind a 1I 7 FIGURE 14 W42 0 WIRE FEEDER CIRCUIT DIAGRAM WITH LEAD KIT WELDMATIC 2555 MANUAL Page 23 BEXT 4E310AE GUN ASSEMBLY BE4392 Nozzle 15 BE4E213B End Fitting dins BE7497 Contact Tip 0 6mm 16 BE4305 Cone Nut BE7488 Contact Tip 0 8mm 17 BE2660001 Terminal 7498 Contact 0 9mm 18 80 1520008 Clamp Tm 87490 Contact Tip 1 2mm 19 BE2520017 Strain Relief Flexible 4335 20 8 14 0007 Bushing 4 BE4323R BE1880135 Strain Relief Rigid 5 BE4780 Nut Insu
17. he Output Welding voltage Rotating the control in a clockwise direction will increase the output voltage 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 contro will vary the spot weld time Rotating the dial in a clockwise direction will increase the spot weld time in the range 0 5 2 5 seconds If the Spot Weld mode is not required this feature may be turned off by rotating the control 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 5 2 5 seconds If the Cycle Arc mode is not required this feature may be turned off by rotating both controls fully anti clockwise 7 WIREFEEDER FUSE This 5 Amp standard action fuse protects the 30Vac Wirefeeder supply circuit 6 WELDMATIC 2555 MANUAL 5 INSTALLATION CONNECTION TO ELECTRICAL MAINS POWER SUPPLY The WELDMATIC 255S is factory fitted with a 3 metre 3 core 25 Amps mains power supply cable with a moulded 3 pin 15 Amps Single Phase plug Note The 15 Amp plug is fitted to allow initial comm
18. imer Interval timer Control of the gas solenoid valve Connections to the board and Service points are detailed in the drawing below The circuit is factory adjusted to provide a maximum drive roller speed of 160 rpm pu U o2 f lt lt gt ul m BURNBACK TE ADJUSTMENT MOUNTED ON THE REAR SIDE OF THE PCB tins 00 20 B omm Ux MAX SPEED CONTROL m E C SU wu t N z wn gt Cc 5 8 gt X o FIGURE 12 WIREFEED CONTROL BOARD 20 13 PARTS LIST W42 0 WIREFEEDER WITH CONTROLS ITEM 1 42 10 D RR 220 S c S 9 2 W39 T3Y 9 147 69215 7 7 09 7 70 076 WAD T e 5 2 1 1 32 2 18 eem 921 7 TC 39521 TA A a CP101 0 18 gt E 7 1 7171 OC LO
19. issioning only 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 255S is 25 Amps To obtain rated output current from the WELDMATIC 255S the 25 Amp flexible supply cable must be fitted with a 3 pin plug that is rated for at least 25 Amp and connected to a correctly installed power outlet of at least 25 Amp Note 25 Amps plugs and sockets are not commercially available A 32 Amps 3 pin plug is available from your WIA distributor WIA Part Number for this plug is CLIS6P332 The minimum recommended circuit breaker rating for Weldmatic 2555 is 25 Amps Note The tripping time of a typical 25A circuit breaker can limit the duty cycle available from the Weldmatic 255S 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 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 s
20. king 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 drawn in WELDMATIC 2555 MANUAL Page 15 10 SERVICE INFORMATION POWER SOURCE SOLID STATE RELAY CONTROL BOARD CP107 10 The Solid State Relay Control board and associated Solid State Relay provides the following functions when Power Source is connected to Wirefeeder E Welding transformer ON OFF control in response to an output from the wirefeed control board the contactor function M Output voltage control by means of Phase shifting of the Welding transformer primary voltage as adjusted by the wirefeeder front panel FINE VOLTAGE SELECTION knob Connections to the board are detailed in the drawing below RECTIFIER THERMOSTAT SOLID STATE RELAY VE CONTROL SOLID STATE RELAY VE 30V AC FINE VOLTAGE W FINE VOLTAGE CW MOUNTING HOLES L E D IS LIT WHEN FINE VOLTAGE POTENTIOMETER CIRCUIT 15 COMPLETE FIGURE 9 SOLID STATE RELAY CONTROL BOARD WELDMATIC 2555 MANUAL Page 16 11 PARTS LIST WELDMATIC 2555 POWER SOURCE ITEM PART DER 107 33 Includes g 106 0 1 ESTER 107 41 ee ell 107 10 qi CP106 0 2 3 CP107 41 2 12 ETE 107 41 1
21. lator 22 BE2280002 Screw N BE1370117 Insulator 29 es AOA Insulated Link 1370116 Body Tube 24 BE4816 Nut 1780006 Handle Kit 25 BE5060 Euro Block Dos BE5662 Trigger Assembly 26 BE4421 O Ring 10 BE1880004 Screw Kit 27 BE9165 O Ring Small 14 1480012 Cable Assembly 3M ox 28 BE43110 Liner 0 9mm 1 2mm 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 15 BEXT 4E310AE 300 AMP GUN CABLE ASSEMBLY 24 WELDMATIC 2555 MANUAL W40 1 MOTOR amp TWO ROLL DRIVE ASSEMBLY ITEM PARTI DESCRIPTION en 6 071 ce ater re Motor amp Gearbox VR blau Screw M6x12 s P NEN W26 0 4 cotes Key cut e MP TS Toi ts Feed Plate 5 RE W260 6 Feed Roll 0 9 1 2mm o NER MM E WT UIB Positioning Screw e ER LA PUT T pP Axle Bu MEUM Pressure Arm com
22. on Dioxide 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 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 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 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 Wirefeed speed Welding arc voltage 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 l
23. ow 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 The welding current should be chosen to suit the thickness of the metal to be welded It is important to check that the deposited weld provides sufficient strength to suit the application WELDMATIC 2555 MANUAL Page 11 A good weld will have the characteristics illustrated in Figure 6 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 7 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 6 GOOD WELD FIGURE 7 BAD WELD GUN POSITION For down hand fillet welding the gun is normally positioned as shown in Figure 8 below with the nozzle end pointing in the direction of travel FIGURE 8 GUN POSITION 12 WELDMATIC 2555 MANUAL 8 GENERAL MAINTENANCE 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
24. plete Includes A acne eats 77175 Renee ee Axle 52 NE VR ER ATONE Pressure Arm EC EO 7 177 e ix Spacer narrow 4 5 W27 1 8 0 097 Pressure Roll 5 Spacer large DD W27 1 10 Axle Clip iA Pis Un Inlet Guide TO Sete 721711 Pressure Screw complete Includes ince Css W2 T 112 a uites os Thumbscrew 27 1120 eee Spring MO W27 1 14 Base 0 2721715 Pressure Link ES E Ga W27 1 16 Pressure Screw Axle T WA TS Spring PE 27 1 18 jn E W2 721713 eterne External Circlip 4mm ID 2 7217 19 External Circlip 5mm ID ALTERNATIVE PARTS WW26 1 8 sese Feed Roll 0 8 1 0mm o3 Pie rere 6 27078 Feed Roll 1 0 1 2mm E WR26 3 8 Feed Roll 1 0 1 2mm Alum 296 4 95 Feed Roll 1 2 1 6mm WV 2629 6 Feed Roll 0 9 1 2mm 26 5 8 Feed Roll 1 2 1 6mm Knurled s MM W26 T718 casses o eese
25. size drive rollers are shown in Section 11 Check also that the correct size contact tip is fitted to the gun Gun part numbers are shown in Section 12 Return the top roller to the closed position and with the machine energised close the gun switch to feed wire through the gun cable Adjust the compression screw to provide just sufficient clamping of the drive rolls drive to achieve constant wirefeed Do not over tighten the compression screw as the consumable wire can be crushed leading to erratic wirefeed 8 WELDMATIC 2555 MANUAL OUTPUT VOLTAGE POLARITY The design of the WELDMATIC 255S allows external selection of the output voltage polarity 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 4 below 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 so
26. 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
27. sulating Bush 1 Female Insulating Bush 09 Output Terminal Assembly 2 Steel Chain 650mm 25 3 Core Flex 32 250 3 Pin Plug Not Supplied amp Not Shown Handle Assembly 00 WELDMATIC 2555 MANUAL Page 17 LOOM ASSY HIGH VOLTAGE LOOM ASSY LOW VOLTAGE PARTS NOT SHOWN 9 2 A e lle d d dol FIGURE 10 WELDMATIC 255 POWER SOURCE ASSEMBLY WELDMATIC 2555 MANUAL Page 18 2 08 Nabe N 9 3 83H3045NUSI 10 9 9 418 LHI pce 103 4 13 fS 4158909 2 142 14 m YOLAANANI 1 8 32 8098 NIG 117 indino AES CP G 1 S zI Naa 3 01129492 3314311233 yawaoasnual 2 SNIdN4M_ 401 FIGURE 11 CP107 0 CIRCUIT DIAGRAM WELDMATIC 2555 MANUAL Page 19 12 SERVICE INFORMATION REMOTE WIREFEEDER WIREFEED CONTROL BOARD W42 10 The Wirefeed control board provides the following circuit functions when Power Source is connected to Wirefeeder Wirefeed motor ON OFF control in response to the gun switch 8 Speed control of the wireteed motor Burn back control Braking of the wirefeed motor at end of weld Spot weld t
28. t 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 2555 MANUAL Page 2 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 l
29. ufficient slack in the cable so that the terminated wires are not in tension CABLE CLAMP EARTH CONNECTION GREEN YELLOW WIRE i Q CABLE TIE 2 AH 1 Li X PLASTIC BUSH BLUE WIRES BACK PANEL BROWN WIRE 3 CORE POWER CABLE TERMINAL BLOCK FIGURE 2 CONNECTION OF SUPPLY FLEXIBLE CABLE 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 inter connecting lead kit to the connector supplied with the flow regulator and secure with the clamp aiso supplied WELDMATIC 1755 MANUAL Page 5 3 FITTING THE GAS BOTTLE Fit the gas regulator to the gas cylinder DO NOT apply oil or grease to these connections Fit the gas connector supplied with the regulator to the gas hose of the welder and secure it with the O clip supplied Always ensure the gas regulator adjusting knob is fully released before opening the gas cylinder valve Failure to observe this practice can result in damage to the regulator 5 4 FITTING THE GUN CABLE The gun cable is attached to the power source via a Euro adaptor which incorporates all required connection points for welding current shielding gas and gun switch control To fit the g
30. ult to earth Replace power source is switched on if faulty Check control transformer for short circuit or fault to earth Replace if faulty Mains fuses blow or circuit Check welding transformer for shorted turns Replace if faulty breaker trips instantly when Check rectifier for shorted diodes Replace if faulty gun switch is closed Mains fuses blow or circuit Check that the recommended fuse or circuit breaker rating has been breaker trips when welding used UNSATISFACTORY WELDING PERFORMANCE AND RESULTS 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 caused by poor wirefeed Check if there is too much drive roller pressure on wire Check spool holder is rotating smoothly Check that gun liner is not too short and is fitted correctly Refer to page 23 for fitting instructions Constant poor arc Check correct polarity has been selected for work and weld cables Refer to page 8 characteristics 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 Porosity in weld caused by Check gas solenoid Replace if faulty lack of shielding gas Check that the correct gas flow rate has been set Check for leaks in gas hose Replace if lea
31. un cable engage the mating parts of the male and female Euro connectors then rotate the locking ring clockwise to firmly secure the connection 5 5 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 6 FEEDING THE CONSUMABLE WIRE Open the two roll drive mechanism by drawing the pressure spring outwards allowing the upper roller assembly to be rotated away from the driven roller The end of the welding wire can now be passed through the inlet guide over the bottom driven roller and into the gun cable assembly Check that the drive roller groove is correct for the wire in use The appropriate size is stamped on the visible side of the installed roller Part numbers for alternate
32. 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 order to obtain results from the G M A W process the wirefeed must be smooth and constant It is therefore important to observe the following points 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 23 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 Replace the welding tip as it becomes worn Keep the wire drive mechanism clean Periodically check the drive rollers for wear and for free rotation E 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 WELDMATIC 2555 MANUAL Page 13 9 TROUBLE SHOOTING Turn on mains supply switch Check mains voltage fuses or circuit breaker Check all primary connections in power source and primary plug Power source has no output Check control lead is plugged to front socket of power source when gun switch closed and Check 5A wirefeeder fuse on power source Replace if blown
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