CP104 Weldmatic 150 Manual - Welding Industries of Australia
Contents
1. 12 SEE TO sae Service InformatiOon eani xe eene P 13 DEC X AB CNET P 16 SOC T2 Safe Practices PO pM Pm P 20 FIGURES PIG MER Power Source 5 le pr Positive Wire Connection P 6 Bo ho eee eee Negative Wire Connection 6 Fig Gana Good 8 giebt Bad WENO eR RS RDS a aE 8 FIG Weld setting 9 mio PRENNE Gun POSINON oro ti ea boobs P 10 mio MP PRU Duty Cycle Chart accessio tote P 11 0 9 Wirefeed Control P 14 tall al Circuit Diagram P 15 DET Power Source P 17 qiio uM ee eee oe Gun Cable Assembly P 18 FIGs Sau W26 Wire Drive Assembly P 19 WELDMATIC 150S MANUAL Page 3 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 any future time When requesting spare parts p2. Gas Regulator amp Flow Gauge CI 104 20 eso Loom Assembly ES CP101 0 20 6 os ice Nut WELDMATIC 1505 MANUAL 1 BOSCO DO O 5 5 silly E L4 ra 5 Pridie gt Ld e oap ap ton t nr e Pe 7 SS r SSI CAN E l WV lion err C QOL HOL GUN CABLE ASSEMBLY SLAM ACTION CATCH GAS REGULATOR ARTS NOT SHOW HINGED DOOR 9 9 6 Q0 090 0 0 0 5 FIGURE 11 WELDMATIC 1505 POWER SOURCE ASSEMBLY Page 18 WELDMATIC 150S MANUAL BEXT2 4E210AE GUN ASSEMBLY 1 2 OONO A 10 14 15 BE4392 Nozzle BE 497 Contact tip 0 6mm BE 488 Contact tip 0 8mm BE7489 Contact tip 0 9mm BE7490 Contact tip 1 2mm BE4335 Head BEAS323R Cap BE4780 Nut Insulator 1370117 Insulator BE1370116 Body Tube BE1780006 Handle Kit BE5662 Trigger BE1880004 Screw Kit BE8681TE Cable 3m 4 213 End Fitting BE4305 Cone Nut 2660001 Terminal BE1520008 Clamp
3. Finger Guard 0 22 Rectifier LIS AM TOS Eg scene rote uoc Control Transformer GE TOS Contactor 24V Terminal Block A AOI MC66 0 8 Flex and Plug 15A a ean MC84 2 1 Cable Clamp ae NEP O EE HF200 1 15 Mounting Foot F209 on Earth Tab 2O IES Cup Terminal A E ATAW Washer 28 S esent Switch O eee eee QUU MEM Hm PCB Standoff Mount B PPE es WB5 10 19 Potentiometer Knob au SESE ESE da Motor and Two Roll Drive C EE TC 290 Plastic Moulding SO EN Central Adaptor TOS96 7 1 isset rne Adaptor Stem TC396 1 8 Power Clamp DON AAE eth TOSI Guide Tube cy E 104 0 1 Gas Valve 24 V AC EELS WTTETTET Hose Barb OU ees xe HOSSR ip MEME ee OCET c PP r O Clip 13mm ross REA OGLE cn O Clip 8mm SA32 0 1 Twistlock Plug cp SATAU0 0 2 Twistlock Socket AA e eS 10 Welding cable 10mm2 ASE o Aa Work Clamp io RN HS 2 4 210 Gun Cable Assembly AT el GW251190
4. M Tf lt TTT 22222222272 5 YOLONGNI 2 ONIOTSM 222222222257 2 i 3ONVMH 5 En PLL LLLL LE LL H3AHO JSNVHL SNIQI3 M SSHOLIMS es lOMiNOO SOVLIOA unc PIIM 19 gt NVA 1NOMJ i TSA 2 3 Hos p lt 3AHOJSNVMHL P 28215 ISI YOLOVINOD gt a D LLI Y 3A1VA SVO Page 16 WELDMATIC 150S MANUAL 11 PARTS LISTS WELDMATIC 150S POWER SOURCE CP104 0 PARTI DESCRIPTION jT ee CP TUTTI Wirespeed PCB Assembly Remote Pots I9 Transformer Inductance Assembly Includes ed AAT 104 16 2 Thermal Overload 104 20 Base Assembly ees CP 104 21 Side Top Cover Fixed GE TUS 22 side cover Opening eicit eve Terminal Bracket sonos e AAT us n eris Support Plate E E ERE 104 0 3 Butt Hinge 2021720 2 22 Slam Catch ee 140 0 1 Handle 22103 28 Axle 103 29 Spool Adaptor E AMTSS S 05 R Clip NS 2 Thrust Washer NOLA ee Fan and Motor 101 0 17
5. Note 2 Duty cycle is defined in Australian Standard AS1966 1 as the ratio of arcing time to 5 minutes in any 5 minute period expressed as a percentage WELDMATIC 150 MANUAL Page 5 4 POWER SOURCE CONTROLS VOLTAGE CONTROL SWITCHES The three voltage control switches together provide 8 steps of output welding voltage adjustment arranged as 4 steps in HIGH range and 4 steps in LOW range Within each range the COARSE switch produces the largest step change of voltage and the FINE switch the smallest step change of voltage Minimum welding voltage is obtained in LOW range with COARSE 1 and FINE 1 selected Maximum welding voltage is obtained in HIGH range with COARSE 2 and FINE 2 selected IMPORTANT Do not operate the Voltage Control switches during welding WIRE SPEED CONTROL This control is used to adjust the feeding rate of the consumable electrode wire Rotating the dial clockwise increases the wirespeed so increasing the welding current Refer to Section 7 of this manual for information with reference to the setting of these controls to obtain the intended welding current A setting chart is also located inside the wire spool enclosure cover WIRE SPEED CONTROL EURO GUN CONNECTOR VOLTAGE CONTROL SWITCHES WELDING OUTPUT TERMINALS FIGURE 1 POWER SOURCE CONTROLS Page 6 WELDMATIC 150 MANUAL 5 WELDING POLARITY SELECTION POSITIVE WIRE Most gas shielded G M A W is carried out with t
6. 10 Axle Shoulder Screw jo T 26 0 11 Pressure Spring W26 0 12 Washer TZ ee W26 0 13 Inlet Guide W26 0 14 Pressure Screw i TAPER W286 0 15 Nut M5 CEP W26 0 16 Retaining Ring Saas Quick Connect Lug WE BS TD Insulating Boot FIGURE 13 W26 TWO ROLL DRIVE ASSEMBLY Page 20 WELDMATIC 150S MANUAL 12 SAFE PRACTICES IN 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 1 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 Recommen
7. BE2520017 Strain Relief flexible 1470007 Bushing 1880135 Strain Relief rigid BE2280002 Screw BE4932 Butt Connector 4816 Nut BE5060 Euro Block BE4421 O Ring BE43110 Liner 0 9 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 12 BEXT2 4E210AE GUN amp CABLE ASSEMBLY WELDMATIC 1505 MANUAL Page 19 W26 MOTOR amp TWO ROLL DRIVE ASSEMBLY ITEM PART DESCRIPTION W26 O 1 Motor and Gearbox th eae tains W26 0 3 Screw M6x12 cO W26 O 4 Key a ERER E W26 0 5 Nut M5 o EEEE 26 0 6 Feed Plate 26 Screw 5 10 W296 0 8 Feed Roll 0 6mm 0 8mm Alternatives W26 5 8 Feed roll 0 9mm 1 2mm W26 6 8 Roll 1 2mm 1 6 mm knurled s PEERS W26 O 9 Screw W26 0
8. arc resulting in a poor weld Best results will be obtained if the surface is clean and dry WELDMATIC 150 MANUAL Page 13 WIREFEED ARC VOLTAGE RELATIONSHIP If the consumable wire is stubbing into the work piece and a steady arc cannot be obtained it is likely that the wirespeed is set too high to suit the welding voltage To correct this situation decrease the wirespeed setting If the arc length is too long increase wirespeed setting NO WELDING CURRENT Check the electrical continuity of the welding current circuit i e work lead work clamp and gun cable connections Check that mains supply voltage is available to the WELDMATIC 1505 i e that the fan is running and the contactor can be heard operating as the gun switch 1 closed lf the thermal overload protection devices have been tripped leave the machine energised with the fan running to achieve the maximum cooling rate If the forgoing checks have been made and have not revealed the fault condition a QUALIFIED SERVICE PERSON should be consulted 10 SERVICE INFORMATION NO TE that the following information is intended for use by Qualified Service Personnel When the unit is energised LE THAL VOLTAGES are present on the electrical and electronic components It is not intended that persons without suitable training and knowledge attempt fo perform service tasks on the components of this Welder Before removing the machine cover ENSURE that the unit is disconnec
9. machine 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 the most satisfactory welding results 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 liner replacement becomes necessary fit only the genuine replacement pari 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 hh Replace the welding tip as it becomes worn or damaged Ensure the tip size is correct for the welding consumable wire in use See Section 11 for gun part numbers Keep the wire drive mechanism clean Periodically check the drive roller for wear or clogging and that the compression roller rotates freely 9 TROUBLE SHOOTING UNSATISFACTORY RESULTS WIREFEED i Erratic wirefeed is the MOST LIKELY cause of failure in all continuous electrode wire welding processes It should therefore be the first point checked when problems occur Refer to the section above WELDING CIRCUIT Ensure that the work clamp is securely tightened onto the work piece so that good electrical contact is achieved Surface contamination of the work piece by water oil grease galvanising paint or oxide layers can severely disturb the welding
10. 4 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 of electrical units should have insulated knobs or covers secured before operation
11. PART 21 09 1 2mm WIA PART 4024812 BERNARD CONTACT TIPS 0 6mm WIA PART No BE7497 0 8mm WIA PART No BE7488 0 9mm WIA PART No BE7489 1 2mm WIA PART No BE7490 WIRE DRIVE ROLLERS 0 6 0 8mm WIA PART No W26 0 8 SUPPLIED 0 971 210 WIA PART No W26 5 8 20 30 40 50 60 70 80 90 100 110 120 130 140 150 1 2 1 6 mm PART No W26 6 8 KNURLED FIGURE 6 WELD SETTING CHARTS Page 10 WELDMATIC 150S MANUAL GUN POSITION For down hand fillet welding with gas shielded consumable wires the gun is normally positioned as in the Figures below with the nozzle end pointing towards the direction of travel For down hand fillet welding with self shielded consumable wires the gun is normally positioned as in the Figures below with the nozzle end pointing away from the direction of travel referred to as dragging the weld Self shielding consumable wires should be operated with approximately 15mm of wire stick out from the welding contact tip gt e GAS SHIELDED WIRE SELF SHIELDED WIRE FIGURE 7 GUN POSITION WELDMATIC 150S MANUAL Page 11 DUTY CYCLE The term duty cycle indicates the percentage welding time available at the rated output current for each 5 min period over 4 hours The WELDMATIC 150 is rated at 135 amps 25 duty cycle If the machine is operated at a reduced welding current a higher duty cycle is available The diagram below illustrates the appropriat
12. 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 weldingindustries com au OWNERS MANUAL WELDMATIC 1505 MODEL CP104 0 REV 11 2000 QUALITY WELDING PRODUCTS SYSTEMS AND SERVICE Page 2 WELDMATIC 1505 MANUAL 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 150 is intended for carrying the machine by hand only DO NOT use this handle for suspending or mounting the machine in any other manner CONTENTS DOC Taten ON m SOC RSC RSS ER P 3 OGC 4 4 Power Source 5 p 5 DOC OD MEN Welding Polarity Selection P 6 DEC Dude Ws teal EN P 7 Sec Basic Welding Information P 8 SEC General 12 Trouble
13. ded shade filter lens Amps TIG MMAW MIG Pulsed MIG 0 100 12 13 100 150 ju orte TB eec 12 13 150 200 10511 TA 12 ines 12 13 200 300 LSS cute jk oe 12 13 12 3 300 400 DN A aia 14 400 500 ee ree Tb 14 500 MC i dubi dE 14 BURN PROTECTION The welding arc is intense and visibly bright ts 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
14. e duty cycle rating for the range of welding currents available from the 150 and so allows the maximum welding time per 5 minute period to be determined The power source is protected by in built over temperature protection devices These will operate if the machine is operated in excess of its current and duty cycle rating If this occurs the fan will continue to run but the machine will not deliver welding current until the unit has cooled sufficiently DUTY CYCLE Maximum welding time per5 mins ot atat anus A a e a un Ta a a E NL E E BE ee Raa A SS afa Lenta ae be ae ae ae ea a annon 100 120 160 Welding Amps 60 80 140 FIGURE 8 DUTY CYCLE RATING CHART Page 12 WELDMATIC 150S MANUAL 8 GENERAL MAINTENANCE Before removing the machine cover ENSURE that the unit is disconnected from the mains power supply When the unit is energised t LE THAL voL TA GES are m i the electrical components enclosed a 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
15. e 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 visibie side of the installed roller Part numbers for alternate size drive rollers are shown Section 11 Check also that the correct size contact tip is fitted to the gun Gun part numbers are shown in section 11 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 Page 8 WELDMATIC 150S MANUAL 7 BASIC WELDING INFORMATION 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 this equipment are Ma Mild Steel Argon 5 to 25 Carbon Dioxide Me Aluminium Argon hi Stainless Steel Argon 1 to 296 Oxygen Consult your gas supplier if more specific information is required SHIELDING GAS FLOW RATE In G M A W one of the functions of the shielding gas is to protect the molten weld pool from the effects of oxygen in t
16. ections 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 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 gun cable 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 In order to obtain the most satisfactory welding results from any G M A W equipment the wirefeed must be smooth and constant 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 For best results use quality WIA consumable wires 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 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 b
17. erable free of oil grease and in electrical parts of metallic particles that can cause short circuits If combustibles are present in the work area do NOT weld or cut Move the work if practicable to an area free of combustibles Avoid paint spray rooms dip tanks storage areas ventilators If the work can not be moved move combustibles at least 10 metres away out of reach of sparks and heat or protect against ignition with suitable and snug fitting fire resistant covers or shields Walls touching combustibles on opposite sides should not be welded on or cut Walls ceilings and floor near work should be protected by heat resistant covers or shields A person acting as Fire Watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if Combustibles including building construction are within 10 metres B 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 167
18. he 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 The WELDMATIC 150 has been designed for use with a range of solid and flux cored electrode wires The charts below can be used to preset the machine for an approximate welding current For each of the eight combinations of voltage control switch settings there is a range of valid wirespeed settings 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 wili stub and stutter and the arc will not be stable If the voltage is too high the arc will be long with metal transfer 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 imp
19. he welding electrode Positive and the work piece Negative To set the machine for this condition connect the lead to the output terminal and the WORK lead to the terminal as in Figure 2 below NEGATIVE WIRE Most Self Shielded flux cored consumables are designed to be operated with the welding electrode Negative and the work piece Positive Check the manufacturers data for the particular consumable to be used To set the machine for this condition connect the GUN lead to the output terminal and the WORK lead to the terminal as in Figure 3 below dee FIGURE 3 NEGATIVE WIRE CONNECTION WELDMATIC 150S MANUAL Page 6 INSTALLATION MAINS POWER SUPPLY The WELDMATIC 150S is designed for a mains power supply of 240 Vac at 50 Hz 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 1505 15 12 Amps and its maximum input current is 28 amps The minimum recommended circuit breaker rating for a Weldmatic 1505 is 16 Amps Note The tripping time of a typical 16A circuit breaker can limit the duty cycle available from the Weldmatic 150S A higher rated circuit breaker can be selected but the mains wiring capacity must be increased to suit SHIELDING GAS SUPPLY Fit the gas regulator to the gas cylinder DO NOT apply oil or grease to these conn
20. lease 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 1 INTRODUCTION The WELDMATIC 1508S is a Gas Metal Arc welding power source designed for use with gas shielded and self shielding flux cored wires The consumable wire is fed to the welding gun by motor driven drive rollers The arc is struck between the work piece and the end of the wire which melts to form the weld deposit With solid consumable wires the arc occurs in an envelope of shielding gas supplied via the gun from a separate gas cylinder Self shielding wires contain a core of flux which during welding generates gases to shield the arc and the weld pool The flux also leaves a light protective slag over the cooling weld deposit In this way a separate gas supply is not required The WELDMATIC 150 is intended for use with 0 6mm to 0 9mm solid wires and 0 9mm and 1 2mm self shielding consumable wires The smaller wire sizes are recommended for welding at lower currents such as for sheet metal applications Increasing the wire diameter permits higher welding currents to be obtained 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
21. ortant to check that the deposited weld provides sufficient strength to suit the application FIGURE 4 GOOD WELD FIGURE 5 BAD WELD WELDMATIC 150S MANUAL Page 9 A good weld will have the characteristics illustrated in Figure 4 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 5 The weld has not penetrated the joint root and there is poor side wali 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 IMPORTANT Do not operate the Voltage Control switches during welding CARBON STEEL SOLID WIRE 0 6mm CARBON STEEL SOLID WIRE 0 8mm eic SETTINGS E SETTINGS 22 22 12 ROS 12 B 8 9 8 11 11 22 22 2 21 221 12 12 4 11 11 20 30 40 50 60 70 80 90 100110 120 130 140 150 20 30 40 50 60 70 80 90 100 110 120 130 140 150 WELDING AMPS WELDING AMPS CARBON STEEL SOLID WIRE 0 9mm oS SETTINGS CARBON STEEL GASLESS CORED WIRE_0 9mm SETTINGS 22 9 10 m 812 11 22 21 12 5 11 22 8 512 11 22 WELDING CONSUMABLES STEEL SOLID WIRES 5Kg SPOOL WIA PART No ES606M oma WIA PART No ES608M 0 9mm WIA PART 5609 CARBON STEEL GASLESS WIRES 4 5Kg SPOOL 0 9 WIA
22. supplier The 104 0 Package contains WELDMATIC 150 Power source with in built wirefeeder E BERNARD 200 Amp Gun cable Euro connector 3 metres E Work Lead Assembly Gas Regulator This Owners Manual Page 4 3 SPECIFICATIONS WELDMATIC 150 MANUAL This equipment is manufactured in accordance with Australian Standard 51966 1 PRIMARY VOLTAGE RATED PRIMARY CURRENT MAX PRIMARY DEMAND MIN RECOMMENDED CIRCUIT BREAKER FITTED SUPPLY CABLE Note 1 ELECTRODE WIRE SIZE RANGE OPEN CIRCUIT VOLTAGE OUTPUT RATING Note 2 MINIMUM WELDING CURRENT MAX WELDING CURRENT 240 Volts AC Single Phase 50 Hz 16 Amps 30 0 25 Three Core Heavy Duty PVC 15 Amp plug Type Y attachment 0 6mm 1 2mm diameter 18 37 Volts Fan cooled air drawn in through rear fan grille 135 Amps 22 Volts 2596 Duty Cycle 67 Amps 18 Volts 100 Duty Cycle 35 Amps 150 Amps 2096 Duty Cycle L 400mm W 245mm H 390mm including handle 33Kg without wire Note 1 Fora type Y cable attachment if the supply flexible cable is damaged it must be replaced by the manufacturer or their service agent or similarly qualified person in order to avoid a hazard
23. ted from the mains power supply When the unit is LETHAL VOL TA GES are on electrical components enclosed SUPPLY FLEXIBLE CABLE The WELDMATIC 150S is fitted with a 3 metre 3 core Heavy Duty PVC mains power supply cable and standard 15 Amp plug If it becomes necessary to replace the mains power supply cable use only a cable with an equivalent or higher current rating Access to the machine supply terminals is gained by removing the power source side panel opposite to the wire spool enclosure Page 14 WELDMATIC 1505 MANUAL WIREFEED CONTROL BOARD CP104 12 B1 M TO WIREFEEDER TO CONTACTOR MOTOR 2 TO TRANSFORMER SECONDARY WINDING TO TRANSFORMER SECONDARY WINDING TO WIREFEEDER_ MOTOR B2 1 TO CONTACTOR QUICK CONNECT um M cp llis QUICK CONNECT LUGS tT FIT INSULATING BOOTS CW TO LEADS FROM gt gt gt POTENTIOMETER m amass d W Quite POTENTIOMETER FACTORY SET FOR 160 RPM WIRESPEED POTENTIOMETER MOUNTED REMOTELY FROM WIREFEEDER BOARD FIGURE 9 WIREFEED CONTROL BOARD Page 15 MOD 86 3 0f pees ZW A18W3SSV ia 3796 20 5531595 418 O30 TAIHS FIGURE 10 WELDMATIC 1505 CIRCUIT DIAGRAM BAC gt 77222222222 931 193205 dO inser W AoW gt 2222222222
24. 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 1505 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 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 op
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