WELDING INDUSTRIES OF AUSTRALIA OWNERS MANUAL
Contents
1. P 8 Fig Beto 172 e MEE 11 PIQUE Bad Welden anann A eA 11 Fig 8 GUN POSITIONS iini ete EN Noua P 11 Fig 9 sene Solid State Relay Control Board P 15 Fig 10 Power Source Assembly P 17 Fig 11 CP107 1 Circuit Diagram P 18 Fig 12 Wirefeed Control P 19 Fig 13 Wirefeeder 2 P 21 Fig 14 W42 0 Circuit Diagram With Lead Kit 22 Fig 15 Gun Cable Assembly P 23 Fig 16 Wire Drive 22 22 21 P 24 FIGIT uoc AM283 Inter connecting Lead p 25 WELDMATIC 255 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 t2. Spring TOSS W27 14 Base 10 35 e AAT Pe A Da Ko EA ET Pressure Link NA E EEE W27 1 16 Pressure Screw Axle W27 1 17 Spring Tas a W27 1 18 eee Pin TAs W27 1 3 SNe External Circlip 4mm ID VOA im W27 1 19 eh Externai Circlip 5mm ID ALTERNATIVE PARTS E E 26 1 8 Feed Roll 0 8 1 0mm GE X M RON 26 2 8 Feed Roll 1 0 1 2mm b unici 26 3 8 _ Feed Roll 1 0 1 2mm Alum W26 4 8 Feed Roll 1 2 1 6mm 5 W28 5 8 Feed Roll 0 9 1 2mm By ics W26 6 8 Feed Roll 1 2 1 6mm Knurled W28 7 8 Feed Roll 1 0 1 2mm Knurled ee W27 1 13 Inlet Guide 3mm 27 2 13 Inlet Guide 2mm 9 isses W28 2 13N inlet Guide 2mm Nylon FIGURE 16 W40 1 TWO ROLL DRIVE ASSEMBLY WELDMATIC 255S MANUAL Page 25 AM283 INTER CONNECTING LEAD KIT ITEM Vos DESCRIPTION p EET AM280 115 Work Lead includes dedo ier CA BW 2 51 ios citet Na Welding Cable 25mm2 A DD v E Plug C232 CM Work Clamp 300Amp qu
3. HO HIMOA n33 E E m S TUnW 3 LNI 1048 AIAAS 2 AHIM 334310 t8 P93 61 2bn avarii aoe ten gt TT ONT 75 381 81462 8405 quad uouved 4937 HHOM HO LOH AIIAAHIM KE e qv31 ta SATA MS7 NNI 113 4437 Ta FIGURE 14 W42 0 WIRE FEEDER CIRCUIT DIAGRAM WITH LEAD KIT WELDMATIC 255 MANUAL Page 23 BEXT 4E310AE GUN ASSEMBLY T5 BE4392 Nozzle 15 BE4E213B End Fitting 25 1 5 BE7497 Contact Tip 0 6mm 16 BE4305 Cone Nut as BE7488 Contact Tip 0 8mm 17 BE2660001 Terminal e BE7498 Contact Tip 0 9mm 18 BE1520008 Clamp p BE7490 Contact Tip 1 2mm 19 BE2520017 Strain Relief Flexible lt sr BE4335 Head 20 BE1470007 Bushing 4 BE4323R Cap 21 BE1880135 Strain Relief Rigid Dresses BE4780 Nut Insulator 22 BE2280002 Screw Ou BE1370117 Insulator 23 2072 Insulated Link BE1370116 Body Tube 24 4816 Nut 8 BE1780006 Handle Kit 25 BE5060 Euro Block 5662 Trigger Assembly 26 BE4421 O Ring 10 BE1880004 Screw Kit 27 BE9165 O Ring Small 14 BE1480012 Cable Assembly 3M 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 W
4. 8 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 roller 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 Drive roller and tip details are available in Section 11 of this manual Return the pressure arm to the closed position and adjust the compression screw to provide sufficient clamping of the drive rolls drive to achieve constant wirefeed Do not over tighten Page 8 WELDMATIC 255S MANUAL OUTPUT VOLTAGE POLARITY The design of the WELDMATIC 255 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 WWORK lead plug i
5. factory adjusted to provide a maximum drive roller speed of 160 rpm BURNBACK ADJUSTMENT MOUNTED ON THE REAR SIDE 777 E mammal 2 0 afi Se OJ c MAX SPEED CONTROL GUN SWITCH INTERVAL SPOT SPOT TIME POT POWER ON LED WIRE SPEED POT FIGURE 12 WIREFEED CONTROL BOARD Page 20 13 PARTS LIST W42 0 WIREFEEDER WITH CONTROLS PART Fcc u N 42 10 41 20 39 12 a en 39 13 SIVE N e W39 14Y cu ew ud 39 15 Pie WV39 1GY usen Ta WAO 4 7e es terri 11 32 2 W39 17 li Kev n E N SEWA 1 396 12 uin mim TAS 101 0 18 W11 117 ile OCES ae AM177 Ss Includes UH EE 133 3 ON heo 42 18 1N30 20 x ribi Includes T meines 4 36 2 min WA2 21 iE Includes T8515 inn cP27 11 26 18 2 ln GP101 11 8 ux NOs Oe AS W17 0 11 TO
6. is done check that area is free of sparks glowing embers and flames A tank or drum which has contained combustibles can produce flammable vapours when heated Such a container must never be welded on or cut unless it has first been cleaned as described in AS 1674 1974 the S A A Cutting and Welding Safety Code This includes a thorough steam or caustic cleaning or a solvent or water washing depending on the combustible s solubility followed by purging and inerting with nitrogen or carbon dioxide and using protective equipment as recommended in AS 1674 1974 Water filling just below working level may substitute for inerting Hollow castings or containers must be vented before welding or cutting They can explode Never weld or cut where the air may contain flammable dust gas or liquid vapours SHOCK PREVENTION Exposed conductors or other bare metal in the welding circuit or ungrounded electrically alive equipment can fatally shock a person whose body becomes a conductor Ensure that the machine is correctly connected and earthed If unsure have machine installed by a qualified electrician On mobile or portable equipment regularly inspect condition of trailing power leads and connecting plugs Repair or replace damaged leads Fully insulated electrode holders should be used Do not use holders with protruding screws Fully insulated lock type connectors should be used to join welding cable lengths Terminals and other exposed parts
7. of electrical units should have insulated knobs or covers secured before operation
8. 5S 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 N803 30A 16V 255A 27V e Tej TO uv ww ae 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 255S 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 is 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 the 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 control will vary the spot weld time Rotating the dial in a clockwise direction will increase the spot weld time in the ra
9. ENTION 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 ihe 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 E Openings concealed or visible in floors or walls within 10 metres may expose combustibles to sparks E Combustibles adjacent to walls ceilings roofs or metal partitions can be ignited by radiant or conducted heat After work
10. ETEA MC14 0111 nis N NE 192 451 eius SCGO030M Oficios itur iut 107 1 4 20 CP42 39 cese WELDMATIC 2555 MANUAL DESCRIPTION Rectifier Assembly Rectifier Assembly with Thermal overload Solid State Relay Heatsink Assy 480V PCB Assy Solid State Relay Control Solid State Relay 480V Heatsink Dust Shield Welding Transformer Assembly inc Wire Loom Inductance Assembly inc Overload Capacitor Bank Mounting Bracket Capacitor 4 Capacitor Rail 2 Discharge Resistor 4 Base Assembly Castor Wheel 2 Front Panel Back Panel Side Panel 2 Top Pane Shelf Panel Rubber Tyre Wheel 2 Ratchet Cap 2 Terminal Block 3 position Fuse Holder Fuse 5 Amp Standard Action Cooling Fan 415V Fan Resistor Not Shown Auxiliary Transformer Cable Inductor End to Capacitor Neg Rail Cable Transformer to Rectifier AC Cable Capacitor Pos Rail to Pos O P Terminal Cable Limit Ind Start to Rectifier Neg Cable Capacitor Pos Rail to Rectifier Pos Cable Inductor Start to Neg O P Terminal Busbar Transformer to Rectifier AC Switch Coarse Loom Assembly High Voltage Not Shown Loom Assembly Low Voltage Not Shown Cable Clamp Male Insulating Bush Female Insulating Bush Output Terminal Assembly 2 Steel Chain 650mm Primary Flex Handle Assembly WELDMATIC 255 MANUAL Page 17 m UD l
11. INDER amp REGULATOR WORK CLAMP r FIGURE 3 REMOTE WIREFEEDER CONNECTIONS FITTING THE GUN CABLE The BERNARD BEXT2 4E310AE gun cable is equipped with a Euro wirefeeder connector which incorporates all required connection points to the gun cable for welding current shielding gas and gun switch control To attach the gun cable to the W42 0 wirefeeding mechanism engage the mating parts of the male and female Euro connectors then rotate the locking ring clockwise to firmly secure the connection FITTING THE CONSUMABLE WIRE The quality of the consumable wire greatly affects how reliably a gas metal arc welder will operate For best results when welding mild steel we recommend quality WIA AUSTMIG ES6 Dirty rusty or kinked wire will not feed smoothly through the gun cable and will cause erratic welding Deposits from the wire will clog the gun cable liner requiring it to be replaced prematurely Place the spool of welding wire onto the spoo holder The location pin should mate with a hole provided on the wire spool body Fit the spool retaining R clip supplied Check the adjustment of the spool brake which should be set to prevent over run of the wire spool at the end of a weld without unduly loading the wirefeed motor The braking can be adjusted by the Nyloc nut using a 15 16 AF or 24mm socket wrench FEEDING THE CONSUMABLE WIRE With reference to Figure 16 release the pressure screw 10 and rotate the pressure arm
12. Ls heces HTIO cen coon cates Cabie Lug AM280 2 8 Weld Lead Includes Do ER ME ore CABW25 de ee Welding Cable 25mm2 PIN CIS CX2T L2 lieet Plug gi cde LUT36B oet sito Cable Lug AM283 3 8 Control Lead Includes earner CAB8C32 s csse Cable 8 Core E 283 1 sse ti Plug 6 Pin Bie ioter HA972ET ies Quick Connect Lug Female 6 BOA ena gg Insulator 2 rM AM280 4 8 Gas Hose Includes 62519 Se MARA we es Gas Hose 5mm dise Vani t OCHS 9 O Clip 1 2 2 AM280 1 5 WELD LEAD 283 3 8 GAS HOSE AM280 4 8 FIGURE 17 AM283 INTER CONNECTING LEAD KIT Page 26 WELDMATIC 255S 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 Heaith 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 underne
13. WELDING INDUSTRIES OF AUSTRALIA A DIVISION OF WELDING INDUSTRIES LTD ACN 004 547 111 Head Office and Internationa 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 255 MODEL NO CP107 1 REV A WITH W42 0 WIREFEEDER 09 2000 QUALITY WELDING PRODUCTS SYSTEMS AND SERVICE ALLY Page 2 WELDMATIC 255 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 any other manne
14. arbon Dioxide W 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 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 low the wire will stub and stutter and there
15. ath 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 ive DD 10 12 13 100 150 TT E asks nei 10 nein 12 13 150 200 12 utn 10 11 11512 12 13 200 300 13 ted 11 5 RS 12 13 12 13 300 400 OS j Res T3 xh 14 400 500 Sud EE Els T 14 500 AUTRE r E aseno kek n 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 us
16. des CPA3 25 eae 7a M AE ENS 102 12 8 105 31 2 106 20 2 43 23 Includes 671 LEA 42 24 6 107 22 ies CP43 21Y 24 iine TO XL CP106 25Y Tl casei 44 22 E a 42 0 3 13 cnet sd MCc11 53 6 qb asl ay Cu oec K RE T MK8 3 x itum 157 sno ANTAL O ESAGSA ee 44 0 2 107 1 3 107 1 1 E 107 44 eee iE 107 45 DN ume CP107 48 iue 22 x tease GP 107 52 ouis D cm CP107 253 52 mne N N i CP107 54 5 ces PLE 107 47 DOSE cg tdi W39 0 prm 107 38 107 49 Includes 107 49 1 e E eS BOM m ated 7 74 S E HASSE HOOF eS D E EEE MC14 0 10 E
17. ed 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 255S MANUAL Page 27 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 PREV
18. he wire core By selection of the correct wire composition diameter and shielding gas G M A W can be used for applications ranging from sheetmetai 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 2596 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 1 package contains WELDMATIC 2555 Power source 42 0 Enclosed Wirefeeder with Controls AM283 0 8 inter connecting Lead Kit 8 metre BEXT2 4E310AE BERNARD Gun cable 3 metre Euro connector WGAC24 Regulator and Flowgauge Argon This Owners Manual Page 4 WELDMATIC 25
19. it 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 CABLE CLAMP EARTH CONNECTION GREEN YELLOW WIRE PLASTIC BUSH 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 ihe 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 also supplied WELDMATIC 255S MANUAL Page 7 FITTING THE REMOTE WIREFEEDER The W42 0 remote wirefeeder is connected to the WELDMATIC 255S Power Source using an AM283 inter connecting lead kit The connection details are shown in Figure 3 GAS CYL
20. ithdraw 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 Page 24 WELDMATIC 255S MANUAL W40 1 MOTOR amp TWO ROLL DRIVE ASSEMBLY ITEM DESCRIPTION RR N W28 0 Motor amp Gearbox W26 0 3 Screw M6x12 TR 26 0 4 DH NATTA Feed Plate MH 26 5 8 Feed Roll 0 9 1 2mm eer 27 0 95 422 ed Positioning Screw TES 2 etie Axle W27 1 4 ess Pressure Arm complete Includes uA V 2151 iini Axle GD uiii 27 1 6 Pressure Arm 8 W27 1 7 aa Spacer narrow I W217 1 8 sayey nan sk nen s pun d se PERDAN Pressure Roll te Bo N 2751 0 ae Spacer large aes 27 1 10 gor nd 26 0 13 Inlet Guide 2 Pressure Screw complete Includes Thumbscrew 10 2 ee awe W27 1 20
21. lding gas WELDMATIC 255S 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 E 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 CONTROL 30V AC SOLID STATE RELAY VE SOLID STATE RELAY VE FINE VOLTAGE W FINE VOLTAGE CW MOUNTING HOLES L E D 5 LIT WHEN FINE VOLTAGE POTENTIOMETER CIRCUIT IS COMPLETE FIGURE 9 SOLID STATE RELAY CONTROL BOARD Page 16 11 PARTS LIST WELDMATIC 255S POWER SOURCE ITEM PART 5 cm j ND 107 34 Includes T oet 106 0 1 doa ionem CP107 51 nue EA 10 Sci 12 2 unns 106 1 2 AD 107 41 2 107 41 1 CP107 55L E E e LE 107 42 107 43 inciu
22. nge 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 Page 6 WELDMATIC 255S MANUAL 5 INSTALLATION CONNECTION TO ELECTRICAL MAINS POWER SUPPLY NOTE All electrical work shall only be undertaken by a qualified electrician WELDMATIC 2555 4807 is factory fitted with 3 metre core 30 0 25 Heavy Duty PVC mains power supply cable 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 12 Amps The minimum recommended circuit breaker rating for a Weldmatic 255S is 16 Amps Note The tripping time of a typical 15A 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 su
23. nto 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 5 below 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 The gas valve is energised gas flow commences 8 The power source contactor function is initiated Welding voltage is applied between the work piece and the consumable wire E The wire drive motor is energised Wirefeed commences and the arc is established 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 W 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 the weld pool To adjust the burn back time refer to Figure Section 12 The gas valve is de energised and the flow of shielding gas ceases Page 10 WELDMATIC 255S 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 255S are Mild Steel Argon 5 to 25 C
24. o 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 if wire is slipping on roller assembly Replace feed roll if worn Check if there is too much drive roller pressure on wire caused by poor wirefeed Check gun liner for build up of dirt or blockage Replace if dirty 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 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 Replace 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 drawn in Constant poor arc characteristics Porosity in weld caused by lack of shie
25. oved by the use of dry low pressure compressed air or a vacuum cleaner WIREFEED In 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 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 255S 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 in primary plug Check control lead is plugged to front socket of power source Power source has no power Power source has no output Check 5A wirefeeder fuse on power source Replace if blown Check all connections to W42 10 circuit board in wirefeeder Check control lead for damage or broken solder joint
26. r CONTENTS Sec 1 Irnitro duction iu eio P 3 Sec 2 REGBIVING e ee P 3 uus Specifications nanna P 4 4 Control Locations Power Source and Wirefeeder 5 SAED ucc _ ahd P 6 6 Normal Welding Sequence P 9 SOC eects Basic Welding Information P 10 8 General 12 9 Trouble Shooting P 13 Sec 10 Service Information Power P 15 Sec 11 Parts List Power P 16 12 Service Information Wirefeeder 19 Sec 13 Parts List P 20 Sec 14 Safe MERERI P 26 FIGURES FON Control Locations Power Source and Wirefeeder P 5 Fig 2 Connection of Supply P 6 Fig 3 Remote Wirefeeder Connections P 7 Fig 4 Positive Wire Connection 2 2222 1 P 8 FIGS Negative Wire Connection
27. s in the 6 pin plug Check control transformer in power source for an input voltage of 480Vac and an output voltage of 32Vac Replace if faulty Replace W42 10 circuit board in wirefeeder Gun switch circuit incomplete Check gun switch for continuity with when gun switch is closed and wirefeeder has no power but 1 power source fan is running 2 wirefeeder power light is off Power source has no output 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 ihe 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 overheated Allow thermostats to cool with fan on Check control lead for damage or broken solder joints in the 6 pin plug Power source has no output when gun switch is closed but 1 power source fan is running 2 wirefeeder power light is on open circuit Replace if faulty Check all connections to CP107 10 circuit board in power source Replace CP107 10 circuit board in power source Replace W42 10 circ
28. s sce Seek 200 1 15 205 eo MC36 56 21 5 0 8 2 42 toon PAE VE NIN DP N 41 0 41 W41 0 2 W29 1 20 204 Xe Se mc i 5 10 19 DU on ee oot XE w11 o16 OB oui 5140 0 1 vi 102 0 18 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 Switched 2 Potentiometer 10K A Type Indicator Light Support Foot 4 Male Bush Female Bush Cable Clamp Hinge L H Hinge R H Slam Action Latch 2 Small Knob 2 Large Knob 2 Handle PCB Support 4 WELDMATIC 255S MANUAL Page 21 ARTS NOT SHOWN 17 LOOM ASS Y FINE VOLTAGE POTS 18 LOOM ASS Y WIREFEED REMOTE POTS FIGURE 13 W42 0 WIREFEEDER WITH CONTROLS WELDMATIC 255S MANUAL Page 22 AATVA 899 WETS 1idn7518
29. t lt o 5 IL x E O LD T T 2 C RT gt gt gt O Pa QU 22 lt lt gt a e O lt e ay zz 8 352 CD mh I PE Pe cL ma i amp 9 9 6 9 O0 FIGURE 10 WELDMATIC 2558 POWER SOURCE ASSEMBLY WELDMATIC 255S MANUAL 2 EZO Page 18 ZHOG ABB i 3 31J24 0 JS HN U 1 1041 02 i 933 434 1 VE A18 H ULSOHS3HI u TO JINYLINGNI 9419737 nn ub d SSE Es HOLIMS 15193 ADVLION 334409 MSS i z 1 n88 81 4809143 VD ee ee Se dem EE ff 7 q YOLINGNI SNIQ13n NEI j 808 781 FP TF TI XNU8 301199393 331411238 ygu B FIGURE 11 CP107 1 CIRCUIT DIAGRAM WELDMATIC 255S MANUAL Page 19 12 SERVICE INFORMATION REMOTE WIREFEEDER WIREFEED CONTROL BOARD W42 10 The Wirefeed contro board provides the following circuit functions when Power Source is connected to Wirefeeder Wirefeed motor ON OFF control in response to the gun switch Speed control of the wirefeed motor Burn back control Braking of the wirefeed motor at end of weld Spot weld timer Interval timer Control of the gas solenoid valve Connections to the board and Service points are detailed in the drawing below The circuit is
30. uit board in wirefeeder Check solid state relay in power source Switch off mains power and After cooling check rectifier thermostat and inductance thermostat for 3 there is wirefeed Live output all the time when power source is switched on disconnect wires from terminals 3 amp 4 of solid state relay Switch on and gun Switch is off mains power and if output is still live replace solid state relay 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 Check control lead for interna bridging of wires Replace W42 10 circuit board in wirefeeder Replace CP107 10 circuit board in power source Wirefeeder fuse blows instantly when power source is switched on Too much drive roller pressure on wire Reduce pressure Check gun liner for build up of dirt or blockage Replace if dirty Wirefeeder fuse blows after a period of welding Page 14 WELDMATIC 255S MANUAL TROUBLE SHOOTING cont Mains fuses blow or circuit Check welding transformer for a fault to earth Replace if faulty breaker trips instantly when Check fan in power source for short circuit or fault to earth Replace power source is switched on if faulty Check control transformer for short circuit or fault t
31. 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 255S 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 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 b b 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 Page 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 wirefeeder covers be removed and any accumulated dust be rem
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