CP109-1 Weldmatic 215S with W52 Feeder Manual
Contents
1. P 21 SEC IGu Sale Practices 445a yi k ta n ilk e k naya k sk NANDO P 22 FIGURES PIGS E E Power Source Control Locations P 5 PG Anata Connection of Supply Cable P 6 le EE Remote Wirefeeder Connection eeecs411114 P 7 FIJA nein Positive Wire Connechon P 8 al io eee e Negative Wire Connection P 8 Fig s PNE Good Wald couvert kek kk testis P 10 ile DE Bad Welches b n p eai lana fee P 10 Fig 8 Gun Positi n aaa P 10 Fong CP109 10 Contro Board P 14 Fig 10 n CP109 0 Circuit Diagram esses P 15 air E EEN Power Source Assembly U P 17 Fig 12 5 5ka2 545 2 a Remote Wirefeeder A A Eiii aaa P 18 ele By IG s N Wire Drive Assembly a P 19 Fig 14 AM297 interconnecting Lead Kit P 20 gile WEST AA Gun Cable Assembly E P 21 WELDMATIC 2155 MANUAL Page 3 1 INTRODUCTION Gas Metal Arc Welding G M A W is a welding process where a consumable wire is fed by motor driven drive rollers to a welding gun and where welding current is supplied from the welding power source The welding arc is struck between the work piece and the end of the wire which melts into the weld pool The arc and the weld pool are shielded by gas flow from the gun or in the case of self shielded wires by gases generated by the wire core By select2. Rod Hinge Not Shown CIE W 10 10 nanana Potentiometer Knob Small 2 Jl deterior E w11 o1e Potentiometer Knob Large SE DO N N 62513 ceste tt Black Oxy Single Hose D lake naaalagaan SCGO03OM ss Steel Chain 650mm Sf na eec ngaba E E EE Rubber Grommet 5D ceste CP42 3D csse Handle Assy Dd utendi WFO0041 6 ul aaa Plastic Cover p W39 0 1 aaa Switch 2 80 esses Le LAN Cable Clamp 94 ctis BBA210 1 Busbar Inductance Bananas BBA320 1 PAA Busbar Inductance to Output ve 80 uon teen ELE eege Nee Busbar Rectifier ve to Inductance Of c scade BBAS500 1 kelan Busbar Rectifier ve to Output ve AA efectos MC14 0 10 Male Insulating Bush For Flex Cord Not Shown MERE MC14 0 11 Female Insulating Bush For Flex Cord Not Shown NUN CP109 40 CP109 1 Owner s Manual Not Shown WELDMATIC 2155 MANUAL Page 17 2 i FIGURE 10 WELDMATIC 2155 POWER SOURCE ASSEMBLY Page 18 WELDMATIC 2155 MANUAL 12 PARTS LIST W52 0 REMOTE WIREFEEDER ASSEMBLY ITEM PART DESCRIPTION jm EID WII Wirefeeder Case TERCER AM TT eue Spool holder assembly e tee eene w21 11 e Plastic dust flap mounting rod LN AM1538 2 44xxxxx Plastic dust flap Dita EN CP109 7 gay ele
3. the time when mains power is power and disconnect yellow wire from gate terminal of triac Switch on mains power and if output is still live replace triac Replace CP109 10 control board Power source has low weld Check welding circuit is making good electrical connection output Check all cable connections in power source for hot spots Power source has no weld output Check all cable connections to coarse and fine switches variation when coarse and fine Check coarse and fine switches Replace if faulty Check welding transformer for a primary fault to earth Replace if faulty applied and gun switch is off Switches are operated Mains fuses blow or circuit breaker trips instantly when mains voltage is applied Check fan in power source for short circuit or fault to earth Replace if faulty Check welding transformer for shorted turns Replace if faulty Check rectifier for shorted diodes Replace if faulty Mains fuses blow or circuit breaker trips instantly when gun switch is closed Check that the recommended fuse or circuit breaker rating has been Mains fuses blow or circuit breaker trips when welding used Consider upgrading to larger fuse or circuit breaker amp wiring WELDMATIC 2155 MANUAL Page 13 TROUBLE SHOOTING cont UNSATISFACTORY WELDING PERFORMANCE AND RESULTS Erratic arc characteristics Check gun liner for build up of dirt or blockage Rep
4. FIGURE 13 CP109 7 TWO ROLL DRIVE ASSEMBLY Page 20 WELDMATIC 2155 MANUAL AM297 INTER CONNECTING LEAD KIT ITEM PART3 rn EIE DESCRIPTION M cres rer sess AM297 2 8 0000aaaaaneeeeeeee Weld Lead Includes deae had acts CABW25 LT s a aa Welding Cable 25mm2 ur N sese xe WGECS3 expe HRS Plug UR DEE ah E 20 BEE Cable Lug EE AM297 3 8 a Control Lead Includes 2 es CABA4C32 ua Cable 4 Core Peon are US EJ36 3 add QC 6 3MM Tab 8 KE RE E1138 a Insulator 4 e REN t KG AM297 1 8 Gas Hose Includes 9 DO e 62513 ice aaa Gas Hose 5mm MM S OCA Bis n etn O Clip 1 2 rc DECEM AM208 1 Double Ended Hose Tail KE WEE e Lk EE Hose Clamp Wo ssl dates CP4105 23 ose Cable amp Work Clamp Assembly Includes A embed CABWA2 5 ius haces Welding Cable 25mm2 WGWO 2 Work Clamp DEE WGE EE Plug LE H1366 enne Cable Lug 1 WELDING LEAD 8 5m BLU BLU BLK gt BLK BRN BRN GRY BLK GRY BLK 2 CONTROL CABLE 8 5m 3 GAS HOSE 8 5m 4 WORK LEAD 3m FIGURE 14 AM297 INTER CONNECTING LEAD KIT WELDMATIC 2155 MANUAL 15 PARTS LIST BEXT2 4E210AE GUN ASSEMBLY ITEM DESCRIPTION PART 1 IN 0774 BE4392 Contact tip 0 6mm BE7497 Contact tip 0 8mm BE7488 Contact tip 0 9mm BE7489 Contact tip 1 2mm BE7490 3 Headset BE4335 4 GAP aaa man BE4323R 5 Nut Insulator BE4780 6 Insulato
5. P 6 D iier Connection To Electrical Mains Power Supply P 6 Co AA zeber yan bek Fitting The Gas Botte P 7 m APAN Fitting Remote Wirefeeder P 7 oT ET Fitting The Gun Cable aa P 7 o MEER TAM Fitting The Consumable Wire P 7 D Sa Heyet en neee Feeding The Consumable Wire P 7 Ge Output Voltage Polarity Selection 000000002 P 8 Sec Normal Welding Sequence 0000seseeacecceeeerieenene P 9 c A PEN Weld EE E EE P 9 ARA Weld ENG E P 9 DODGE d AR Basic Welding Information P 9 Lt deett Choice Of Shielding Gas P 9 RT RUNE NN Shielding Gas Flow Rate a n nnnona00nrono0n0eeeeeene P 9 v pic an S v Establishing A Weld Setting P 9 TE oe GuriPositlon is neret x rigen P 10 Sec 8 General Maintenance jj mms P 11 Sec 9 Trouble Shooting ET P 12 Sec 10 Service Information a P 14 Sec 11 Parts List Power Source Assembly P 16 SOC PAN Parts List Remote Wirefeeder P 18 DBP 19 eese Parts List Wire Drive Assembly P 19 Sec 14 Parts List Interconnecting Lead Kit P 10 986 15 oet sa k Parts List Gun Cable Assembly
6. primary current for a Weldmatic 215S is 16 Amps The minimum recommended circuit breaker rating for a Weldmatic 215S is 20 Amps Note The tripping time of a typical 20A circuit breaker may limit the duty cycle available from the Weldmatic 215S A higher rated circuit breaker can be 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 sufficient slack in the cable so that the terminated wires are not in tension BACK CABLE BLUE BROWN TERMINAL PANEL WIRE BLOCK 3 CORE POWER CABLE GREEN YELLOW WIRE PLASTIC EARTH BUSH CONNECTION FIGURE 2 CONNECTION OF SUPPLY FLEXIBLE CABLE WELDMATIC 2155 MANUAL Page 7 5 2 FITTING THE GAS BOTTLE Depending on configuration of the cylinder to be used the gas flowmeter regulator may be fitted directly to the cylinder or in conjunction with an elbow fitting DO NOT apply any grease to these joints and tighten the nuts securely Fit the en
7. RMATION 7 1 CHOICE OF SHIELDING GAS The choice of shielding gas is largely determined by the consumable wire to be used Many proprietary shielding gas mixtures are available The recommended shielding gases for use with the WELDMATIC 2155 are BR Mild Steel Argon 5 to 2596 Carbon Dioxide BW Aluminium Argon B Stainless Steel Argon 1 to 2 Oxygen Consult your gas supplier if more specific information is required 7 2 SHIELDING GAS FLOW RATE In G M A welding one of the functions of the shielding gas is to protect the molten weld pool from the effects of oxygen in the atmosphere Without this protection the weld deposit becomes honeycombed in appearance an effect which is described as weld porosity In draft free conditions the gas flow rate required to give adequate protection is typically 10 litres min In situations where drafts cannot be avoided it may be necessary to increase this rate and or to provide screening of the work area Weld porosity can also be caused by air entering the gas stream through a damaged hose loose gas connection or from restriction in the nozzle such as from excess build up of spatter 7 3 ESTABLISHING A WELD SETTING Once the consumable wire type wire size and shielding gas have been chosen the two variables which are adjusted in order to obtain a stable arc are BW Wirefeed speed BW Welding arc voltage Page 10 WELDMA
8. TIC 2155 MANUAL The wirefeed rate determines the welding current increasing the feed rate increases the current and decreasing it decreases current The selected wirefeed rate must be matched with sufficient arc voltage an increase of wirefeed rate requires an increase of arc voltage If the voltage is too low the wire will stub and stutter and there will not be a steady arc If the voltage is too high the arc will be long with the metal transfer within the arc occurring as a series of large droplets IMPORTANT Do not operate the Voltage Control switches during welding The welding current should be chosen to suit the thickness of the metal to be welded It is important to check that the deposited weld provides sufficient strength to suit the application A good weid 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 7 4 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
9. 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 215S MODEL NO CP109 1 REV A 11 2000 QUALITY WELDING PRODUCTS SYSTEMS AND SERVICE ERA Page 2 WELDMATIC 2155 MANUAL The information contained in this manual is set out to enabie you to properly maintain your new equipment and ensure that you obtain maximum operating efficiency Please ensure that this information is kept in a safe place for ready reference when required at any future time When requesting spare parts please quote the model and serial number of the machine and part number of the item required All relevant numbers are shown in lists contained in this manual Failure to supply this information may result in unnecessary delays in supplying the correct parts SAFETY Before this equipment is put into operation the Safe Practices section at the back of the manual must be read completely This will help to avoid possible injury due to misuse or improper welding applications CONTENTS S8651 PARA PAA age e lle IL AA AA ALES DA O096 2 conseua FRECOIVING GANAN EE eles P 3 S863 ee ee Specifications EE P 4 Sec 4 Power Source Controls E P 5 SO Ola ams Nakalaan even na Ht MIR ee bat ta ie
10. ame to form PHOSGENE a highly toxic gas and lung and eye irritating products The ultra violet radiant energy of the arc can also decompose trichlorethylene and perchlorethylene vapours to form phosgene Do not weld or cut where solvent vapours can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichlorethylene or percholorethylene FIRE AND EXPLOSION PREVENTION Be aware that flying sparks or falling slag can pass through cracks along pipes through windows or doors and through wall or floor openings out of sight of the operator Sparks and slag can travel up to 10 metres from the arc Keep equipment clean and operable free of oil grease and in electrical parts of metallic particles that can cause short circuits If combustibles are present in the work area do NOT weld or cut Move the work if practicable to an area free of combustibles Avoid paint spray rooms dip tanks storage areas ventilators If the work can not be moved move combustibles at least 10 metres away out of reach of sparks and heat or protect against ignition with suitable and snug fitting fire resistant covers or shields Walls touching combustibles on opposite sides should not be welded on or cut Walls ceilings and floor near work should be protected by heat resistant covers or shields A person acting as Fire Watcher must be standing by with suitable fire extinguis
11. cessive This also may be conveniently done each time the wire is replenished Page 12 WELDMATIC 215S MANUAL 9 TROUBLE SHOOTING FAULT REMEDY Power source has no power ie Turn on mains supply switch Check mains voltage fuses or circuit breaker Check all primary connections in power source and in primary plug Check all connections to CP109 10 control board in power source Replace CP109 10 control board 1 power light is off 2 fans are not running Power source has no output but 1 power light is off 2 fans are running Power source overheated Allow thermostats to cool with fans on After cooling if problem still persists check rectifier thermostat Power source has no output and no wirefeed when gun switch is closed but and transformer thermostat for open circuit Replace if faulty 1 power light is on 2 overload light is on Check all connections to CP109 10 control board in power source 3 fans are running Power source has no output and Gun switch circuit incomplete Check gun switch for continuity with no wirefeed when gun switch is ohm meter when switch is pressed Replace if faulty adaptor are making contact with the 2 pins from the gun cable Check triac in rectifier assembly of power source Switch off mains closed but 1 power light is on 2 overload light is off 3 fans are running Power source has live output all
12. d of the gas inlet hose from the back of the machine to the connector supplied with the flow regulator and secure with the clamp also supplied 5 3 FITTING REMOTE WIREFEEDER The W52 0 remote wirefeeder is connected to the WELDMATIC 215S power source using an AM297 extension lead kit The connection details are shown in the diagram below GAS HOSE POWER CABLE GUN CABLE CONNECTOR BLACK C gt BLACK GREY BLACK CONTROL CABLE GREY BLACK BLUE ca RED WELD W52 0 WIRE FEEDER AM297 LEAD KIT POWER SOURCE FIGURE 3 REMOTE WIREFEEDER CONNECTIONS 5 4 FITTING THE GUN CABLE The BERNARD BEXT2 4E210AE 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 wirefeeding mechanism engage the mating parts of the male and female Euro connectors then rotate the locking ring clockwise to firmly secure the connection 5 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
13. direction of travel FIGURE 8 GUN POSITION WELDMATIC 215S MANUAL Page 11 8 GENERAL MAINTENANCE Before removing the machine cover ENSURE that the unit is disconnected from the mains power supply When the unit is energised LETHAL VOLTAGES are present on the electrical components enclosed DUST Care should be taken to prevent excessive build up of dust and dirt within the weiding power source It is recommended that at regular intervals according to the prevailing conditions the machine covers and enclosed wirefeeder covers be removed and any accumulated dust be removed by the use of dry low pressure compressed air or a vacuum cleaner WIREFEED In 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 19 The build up of dust in a cable liner can be minimised by regular purging of the liner with dry compressed air This may be conveniently done each time the wire spool is replaced 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 Check that the consumable wire spool holder rotates smoothly and that the braking action is not ex
14. ety 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 locai exhaust ventilation must be used or each person in the area as well as the operator must wear an air supplied respirator For beryllium both must be used Metals coated with or containing materials that emit fumes should not be heated unless coating is removed from the work surface the area is well ventilated or the operator wears an air supplied respirator Work in a confined space only while it is being ventilated and if necessary while wearing air supplied respirator WELDMATIC 2155 MANUAL Page 23 Vapours from chlorinated solvents can be decomposed by the heat of the arc or fl
15. hine 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
16. hing equipment during and for some time after welding or cutting if 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 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 mac
17. hown 9 2 ee use is CP102 51 2 sss SCR Module Not Shown SSES CP109 32 sss Heatsink Not Shown SAND dudes CP43 23 esses Base Assembly Includes 64 ene CP42 24 6 Castor Wheel 2 p CP109 20Y sss Front Panel OQ uode e aut CP109 24Y ulan Back Panel OQ uox enn CP109 21Y ula Centre Panel Assembly TO MM a AG CP109 23 sss Baffle Panel Tuner CP42 27Y ula Side Cover Fixed Lower Not Shown 212 NEN CP109 28Y sss Door Hinged Not Shown O ri la keda ideo CP42 29Y lansa nanana Top Cover 134 5 nune W29 1 20 AA Slam Action Latch On Door Not Shown 15 need CP43 24Y i css debe Side Cover Not Shown AAP RANG CP42 0 3 eese Rubber Tyre Wheel 2 Tee deg MC11 53 6 enaura ni Ratchet Cap 2 1S E E E E CPT1 0 5 naan Loom Assembly Low Voltage Not Shown TI naaa e E N ae E Blank Hole Plug Not Shown 20 T stein CP109 55 etse Loom Assembly Transformer Not Shown ag EEEN ARAT hn CP109 56 sss Loom Assembly High Voltage Not Shown EE SA140 0 2 Socket Dinsel 25mm 2 EE MKO 2 a aa nand kaaa Terminal Block 2 position SES E A CPZ rO 8 EE Cooling Fan 2 E SK PA AG CP101 0 1 Gas Valve 24V DC Seege WATA as Gas Valve Hose Tail 2 See GE OCE13 5 50 eese O Clip 2 W PEE T E T CP106 0 3 aenaran 20A Flex amp 15A Plug PO amak CP109 15
18. imum drive roller speed of 160 rpm MAXIMUM SPEED CALIBRATION pos ACTIVE 240VAC THERMOSTAT THERMOSTAT T OUTPUT TERMINAL VE OUTPUT TERMINAL VE dang GUN SWITCH ra NEUTRAL 240VAC SECONDARY TRANSFORMER GUN SWITCH SECONDARY TRANSFORMER GAS VALVE WIREFEED MOTOR VE GAS VALVE WIREFEED MOTOR VE FIGURE 9 CP109 10 CONTROL BOARD Page 15 WELDMATIC 2155 MANUAL eg pag 19UH0 SUBI SUBA jejsawiayi lt Jeg ang gt 3 g Ad Zd au Pr sure raynoay paisowuay Ava MS NAg feu JOON 9d ang lt sangria Pan HOLOW DIEN yams ung d weeoueut BANISO IQON Ld gt lt lt UMOJ PE 8 Kea Q333 3YIM 9d BAA SED euo Od JepeajeJ AA Ll l B60id9 Sd Jojonpuy BUIPIBAA SE r a JeinoN 22 L De eo pay to AOES 401 0 MG HOST CO A ba AJ ISOd 3Suvoo Jeunojsue BujpjaAA FIGURE 10 CP109 1 CIRCUIT DIAGRAM Page 16 WELDMATIC 2155 MANUAL 11 PARTS LIST WELDMATIC 2155 POWER SOURCE ITEM PART SA DESCRIPTION EN CP109 10N oaeen PCB Assy Wirefeed P E AEE eda CP109 5L AA Weld Transformer Assy inc Overload amp Wire Loom Includes DAANAN NA CP104 16 2 Thermal Overload Seege ee iiic en CP109 6 occ lst tac inductance Assembly EEN le Rectifier Assembly Includes ccr mm CP106 0 1 Rectifier with Thermal overload E E WE CP3 9 B s cde Thermal Overload Not S
19. ion 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 2155S 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 CP109 0 package contains E WELDMATIC 215S Power source 8 BEXT2 4E210AE BERNARD Gun cable 3 metre Euro connector 8 WGAC24 Regulator and Flow gauge Argon This Owners Manual Page 4 WELDMATIC 2155 MANUAL 3 SPECIFICATIONS Manufactured to Australian standard AS 1966 1 1985 Rated to ISO IEC 60974 1 10 minute duty cyc
20. k ken bbn Motor 2 roll drive amp Euro adaptor assembly D dye y k xad de san zann Hop Cable Clamp Utilux deer Ee ee Cable Clamp Utilux Best DA OE secedere O Clip 5 16 m A lk RR FIGURE 12 W52 0 REMOTE WIREFEEDER WELDMATIC 2155 MANUAL Page 19 13 PARTS LIST CP109 7 MOTOR TWO ROLL DRIVE amp EURO ADAPTOR ASSEMBLY ITEM PART3 uico Rs DESCRIPTION m PE WFO001 1 U Motor amp Gearbox PAR N ET WFO001 2 ulan Euro Gun Adaptor inc Guide amp Gas Connector ce NN DD YN WFO01 3 iu n 2 Roll Feed Plate D Sana deett WEOO0124 unitis Pressure Arm Complete a ns ec N WFO01 4A aa Pressure Roll 30mm Diameter Ls eni WEOOT P Pressure Screw Complete a WFO001 6 ula Insulation Board Do E na WFO01 7 ulanan nananana Insulation Washer e PPT W206 1 8 sss Feed Roll 30mm 0 8 1 0mm Solid Wire 10 oett W21 0 9 eee Positioning Screw Main Gear mana W26 0 13 Inlet Guide ALTERNATIVE PARTS Oy iex W26 0 B nananana Feed Roll 0 6 0 8mm Solid Wire EEN N2158 sss Feed Roll 0 9 1 2mm Solid Wire 9 manna NG W26 Banana Feed Roll 1 0 1 2mm Solid Wire EE W26 4 B anan naa nananasaann Feed Roll 1 2 1 6mm Solid Wire 9 iesus W296 3 8 sess Feed Roll 1 0 1 2mm Aluminium Wire AE W296 T718 sss Feed Roll 1 0 1 2mm Flux Cored Wire 9 enne W26 8 8 sss Feed Roll 1 2 1 6mm Flux Cored Wire PANEL
21. lace if dirty Check that gun liner is not too short and is fitted correctly Refer to caused by poor wirefeed page 19 for fitting instructions Check correct polarity has been selected for work and weld cables Referto page 8 Constant poor arc 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 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 lack of shielding gas drawn in Page 14 WELDMATIC 2155 MANUAL 10 SERVICE INFORMATION CP109 10 CONTROL BOARD The CP109 10 Control board provides the following functions E Welding transformer ON OFF control Wirefeed motor ON OFF control Speed control of the wirefeed motor Braking of the wirefeed motor at end of weld Spot weld timer E Interval timer Gas solenoid valve ON OFF control E Triac ON OFF control phase selected to minimise transformer inrush current E Triac protection by output short circuit detection Connections to the board are detailed in the drawing below The circuit is factory adjusted to provide a max
22. le WELDING INDUSTRIES of AUSTRALIA Weldmatic 215s Made in Australia RATED TO ISO IEC 60974 1 N803 a CLASS INS H COOLING AF Under ISO IEC 60974 1 duty cycle is defined as the ratio of arcing time to an operating time of 10 minutes expressed as a percentage WELDMATIC 215S MANUAL Page 5 4 POWER SOURCE CONTROLS 4 WIRE SPEED CONTROL 5 SPOT TIME CONTROL 6 INTERVAL CONTROL T OVERLOAD INDICATOR GB POWER ON INDICATOR 3 FINE VOLTAGE CONTROL 2 COARSE VOLTAGE CONTROL FIGURE 1 POWER SOURCE CONTROL 1 POWER ON INDICATOR This is illuminated when electrical mains power is connected to the welding power source 2 COARSE VOLTAGE CONTROL This switch provides Coarse adjustment of the Output Welding Voltage over three ranges 3 FINE VOLTAGE CONTROL This switch provides Fine adjustment of the Output Welding Voltage over three ranges 4 WIRE SPEED CONTROL This control provides adjustment of the wirefeed speed Rotating the dial in a clockwise direction will increase the wirefeed speed thereby increasing the welding current 5 SPOT TIME CONTROL When operating the machine in Spot Weld mode this control will vary the spot weld time Rotating the dial in a clockwise direction will increase the spot weld time in the range 0 4 3 0 seconds If the Spot Weld mode is not required this feature may be turned off by rotating the control anti clockwise until it clicks into the minim
23. 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 With reference to Figure 12 release the pressure screw 6 and rotate the pressure arm 4 to the open position The end of the welding wire can now be passed through the inlet guide 11 over the bottom driven roller 9 and into the output wire guide tube Check that the drive roller groove is correct for the wire in 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 pressure screw to provide sufficient clamping of the drive rolls drive to achieve constant wirefeed Do not over tighten Page 8 WELDMATIC 2155 MANUAL 5 7 OUTPUT VOLTAGE POLARITY SELECTION The design of the WELDMATIC 215S allows external selection of the output voltage polarity positive wire or negative wire 5 7 1 POSITIVE WIRE Most solid wire G M A W is carried out with the work piece Negative and the welding consumable wire Positive To set
24. r BE1370117 7 Body Tute BE1370116 8 Handle Kit BE1780006 9 Trigger ets BE5662 10 Screw Kit BE1880004 14 Cable 3m BE8681TE Page 21 ITEM DESCRIPTION PART 15 End Fitting BE4E213B 16 Cone Nut BE4305 17 Terminal BE2660001 18 Camp eos BE1520008 19 Strain Relief BE2520017 20 Bushing BE1470007 21 Strain Relief rigid BE1880135 22 DOTOW xu haa NAN BE2280002 23 Insulated Link H2072 24 Nt stets BE4816 25 Euro Block BE5060 26 O Ring kake kake BE4421 27 Liner 0 9 1 2mm BE43110 To replace liner Disconnect gun cable assembly from the Euro adaptor on the machine case remove nozzle 1 and head 3 Withdraw old liner from the wire feeder end Insert new liner and refit gun cable assembly to Euro adaptor on the machine case At the gun end compress the liner within the gun cable then cut it one contact tip length past the end of the body tube 7 Refit head tip and nozzle FIGURE 15 BEXT2 4E210AE 200 AMP GUN CABLE ASSEMBLY Page 22 WELDMATIC 21585 MANUAL 16 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 a
25. 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 5 7 2 NEGATIVE WIRE Some self shielded flux cored consumables are intended to be operated with the work piece Positive and the consumable wire Negative Refer to the manufacturers data for the particular consumable to be used To set the machine for this condition insert the WORK lead plug into the output socket on the front of the power source Insert inter connecting WELD lead plug into the output socket on the front of the power source See Figure 5 below WORK LEAD FIGURE 5 NEGATIVE WIRE WELDMATIC 2155 MANUAL Page 9 6 NORMAL WELDING SEQUENCE 6 1 WELD START Closing the welding gun switch initiates this sequence of events The gas valve is energised gas flow commences The power source triac function is initiated Welding voltage is applied between the work piece and the consumable wire BR The wire drive motor is energised Wirefeed commences and the arc is established 6 2 WELD END Releasing the gun switch initiates this sequence of events The wire drive motor is de energised and is dynamically braked to a stop The power source triac function is de energised The gas valve is de energised and the flow of shielding gas ceases 7 BASIC WELDING INFO
26. um position 6 INTERVAL CONTROL When operating the machine in Cycle Arc mode this control sets the period between welds The spot time control sets the welding period Rotating the dial in a clockwise direction will increase the interval time in the range 0 4 1 8 seconds If the Cycle Arc mode is not required this feature may be turned off by rotating both controls fully anti clockwise 7 OVERLOAD INDICATOR This is illuminated when the welding load exceeds the operating duty cycle In this event the machine will not deliver welding current until the machine has cooled sufficiently The over temperature thermostats will reset automatically do not switch the machine off as the cooling fan will assist the resetting of the thermostats Page 6 WELDMATIC 2155 MANUAL 5 INSTALLATION 5 1 CONNECTION TO ELECTRICAL MAINS POWER SUPPLY NOTE All electrical work shall only be undertaken by a qualified electrician The WELDMATIC 2155S is factory fitted with a 3 metre 3 core 50 0 25 Heavy Duty PVC mains power supply cabie with moulded 3 pin 15 Amp Single Phase plug A 15 Amp plug and socket is recognisable by a wide Earth pin Power Supply authorities require that equipment fitted with a 15 Amp plug shall ONLY be connected to a 240 Volt 15 Amp power point DO NOT modify the plug The minimum capacity of the mains wiring and power outlet supplying a welder is selected according to the effective primary current of the machine The effective
27. vailable 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 additiona 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 TIG MMAW MIG Pulsed MIG 0 100 TOLA n n RD N t eiis 12 13 100 150 Ina O keit TO iioii 12 13 150 200 12 NANA 10 11 11 12 12 13 200 300 TO secuit Tene 12 13 12 13 300 400 CAN Se eet iS ences 14 400 500 ATE d SE aa TA aan 14 500 EEN mu eden Vat 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 saf
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