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Operators Manual - Welding Industries of Australia
Contents
1. Thermostats Max Wirespeed Adjustment factory Wiredrive set for 195 rpm Motor Contactor coil 30 Vac Gun svvitch Thermistor Thermistor DANGER T 240V Fan circuit Fig 8 PWAOOSN Control Board 18 EAA Quality e Reliability e Performance Weldmatic 8mm amp 10mm ircuit Diagram 10 2 C N X peysoly peeds 8 551 0o 8LLdo Pno Q 6LLdO O 8LLdoO 9d Sd HOLIMS NNS 104 U09 160968 SH G00Y Md K yoj q buen d3 38 JAIM jode awl 1005 JESUISAO OL QIN O lld gt o a JATYA SYS 313 Sma MOTISA DY AQE SHKA 19117989 P1S0LLIS JSNVHL UNJSH Je UL id 8d Maand LSNVAL 11 jEJSOULISULL NMOHE KISHTE HOLS AS GNVLS MOTISA 4 loyeorg NIAID YS qad anjebanN HOLIMS 3 ve ol 9 zova T ge CED zZ any F 7 55 enjisod oo z a L 1 and HOLIAAS ISHVOD Fig 9 Weldmatic 8mm and 10mm Circuit Diagram Model Nos CP118 0 amp CP119 0 Iss A 07708 19 Operators Manual 11 1 Assembly and Parts List Power Source Fig 10 Weldmatic 8mm and 10mm Power Source Assembly 20 ai Quality e Reliability e Performance Weldmatic 8mm amp 10mm Item Part Part Descri
2. FAST will provide faster wire acceleration at arc start giving quicker arts starts suitable for applications such as rapid tack welding Rotating the knob towards SOFT will slow wire acceleration providing a softer start suitable for larger diameter and aluminium wires 2 Overload Indicator This is illuminated when the welding load exceeds the equipments operating duty cycle In this event the equipment will cease to deliver welding current The over temperature thermostats will reset automatically do not switch the equipment off as the cooling fan will assist the resetting of the thermostats Once the machine has cooled sufficiently the thermostat will reset the Overload Indicator will go out and welding may be resumed 3 Spot Time Control When operating in Spot mode this control will vary the spot weld time Rotating the dial in a clockwise direction will increase the spot weld time 4 Fine Voltage Control This switch provides Fine adjustment of the output welding voltage over three ranges Note Minimum welding voltage is obtained with Coarse A and Fine 1 selected Maximum welding voltage is obtained with Coarse C and Fine 3 selected Do not operate the Voltage Control switches during welding Model Nos CP118 0 amp CP119 0 Iss A 07108 7 Operators Manual 5 Coarse Voltage Control This switch provides Coarse adjustment of the output welding voltage over three ranges 6 Wire Speed Con
3. Operators Manual WELDMATIC 8mm VVELDMATIC Omm MADE IN WARRANTY CP118 40 Rev C Weldmatic 8mm Weldmatic 10mm internal wirefeeder Operators Manual Weldmatic MIG welders Weldmatic 8mm CP118 0 Iss A Weldmatic 10mm CP119 0 Iss A 07 08 CP118 40 Rev C Welding Industries of Australia An ITW Company ABN 18 004 547 111 Telephone 1300 300 884 Facsimile 1300 301 884 Email Info welding com au www welding com au Quality e Reliability e Performance Weldmatic 8mm amp 10mm Contents Section General information Page Safe practices 2 Introduction 5 2 Receiving 5 3 Specifications 6 4 Controls 7 5 Installation 9 6 Normal welding sequence 11 7 Basic welding information 12 8 General maintenance 15 9 Trouble shooting 16 10 Service information 18 11 Assembly and parts lists 11 1 Povver source 20 11 2 VVirefeed assembly 22 11 3 Gun and cable assembly 23 12 VVarranty information 24 Model Nos CP118 0 amp CP119 0 Iss A 07708 1 Operators Manual Read first 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 sate place for ready reference when required at any future time When ordering spare parts please quote the model and serial number of the power source and part number of the item required All relevant
4. Fit the end of the gas inlet hose from the back of the power source to the connector Supplied with the gas regulator and secure with the clamp also supplied 10 Fitting The Gun and Cable Assembly The supplied gun cable assembly is equipped with a Euro wirefeeder connector which incorporates all required connection points for welding current shielding gas and gun switch control To attach the gun cable assembly to the wirefeeder 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 Place the spool of welding wire onto the spool holder The location pin should mate with a hole provided on the wire spool body Fit the spool retaining R clip supplied Check the adjustment of the spool brake adjuster 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 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 EAA Quality e Reliability e Performance Feeding the Consumable Wire At the wirefeed assembly
5. amp 10mm Replacement of the cable must be carried out by the manufacturer their service agent or a similarly qualified person Output Voltage Polarity The design of the Weldmatic 8mm and 10mm allows selection of the output voltage polarity Positive Wire G M A W with solid consumable wires including aluminium is carried out with the work piece Negative and the welding wire Positive To setup for this condition connect the WORK lead plug into the output socket on the Power Source and the WELDING lead from the power source into the socket as in Figure 2 To gun cable To work clamp Fig 2 Positive Wire Model Nos CP118 0 amp CP119 0 Iss A 07 08 9 Operators Manual Negative Wire Some self shielded flux cored consumable wires are operated with the work piece Positive and the consumable wire Negative Refer to the manufacturers data for the particular consumable wire to be used To setup for this condition connect the WORK lead plug into the output socket on the Power Source and the WELDING lead trom the power source into the socket as in Figure 3 To gun cable To work clamp Fig 3 Negative Wire Fitting the gas cylinder Place the gas cylinder on the tray at the rear of the optional welder trolley if using Retain the cylinder with the chain provided Fit the gas regulator to the cylinder DO NOT apply grease or oil to these joints
6. Amps Maximum Primary Current 31 Amps 38 Amps Recommended Circuit Breaker 20 Amp 25 Amp Recommended Generator kVA 7 5 kVA 9 5 kVA Rated Output 40 C 10 minute duty cycle time 175 Amp 22 8 V 20 duty 80 Amp 18 V 100 duty 200 Amp 24 V 20 duty 90 Amp 19 5 V 100 duty Welding Current 30 175 Amps 35 200 Amps Open Circuit Voltage 16 5 33 V 17 34V Shipping Weight 72 75 K9 Fitted Supply Plug 15 Amp 15 Amp see note Fitted Supply Cable 15 Amp 20 Amp 30 0 25 Three Core Heavy Duty PVC 50 0 25 Three Core Heavy Duty PVC Cooling Fan cooled air drawn in Fan cooled air drawn in through front grille through front grille Insulation Class H 140 C Rise max Class H 140 C Rise max Spool Sizes 5 kg 15 kg 5kg 15 Wirespeed Max 195 RPM 195 RPM 18 Metres per min 18 Metres per min Wire Size Range mm diameter 0 6 0 9 solid wire 0 8 1 2 cored wire 0 6 0 9 solid wire 0 8 1 2 cored wire Welding Capacity Ti 8mm al Gag 15 Amp plug fitted for initial commissioning only Refer Section 5 EAA Quality e Reliability e Performance 4 Controls Weldmatic 8mm amp 10mm inside wirefeed enclosure OOS Look Fig 1 Power Source Controls 1 Arc start This control can be set to modify arc starting conditions For many applications the control can be set at the mid point Rotating the knob towards
7. 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 vvork 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 titting 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 Model Nos CP118 0 amp CP119 0 Iss A 07 08 3 Operators Manual 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 e 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 roots 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 produc
8. higher duty cycle is available The diagrams below illustrate the appropriate duty cycle rating for the range of welding currents available from the Weldmatic 8mm and 10mm and so allows the maximum welding time per 10 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 Fig 7a Duty Cycle Rating Weldmatic 8mm Fig 7b Duty Cycle Rating Weldmatic 10mm Ka Quality e Reliability e Performance 8 General Maintenance Before removing the equipment cover ENSURE that the equipment is disconnected from the mains power supply When the equipment 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 welding power source It is recommended that at regular intervals according to the prevailing conditions the equipment 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 Most causes of erratic wirefeed can be cured by basic
9. maintenance Check that the Feed rolls are the correct size and type for the wire in use Check also that the drive groove is aligned with the wire and that the groove is not worn Gun cable liner is clear of dust and swart build up When replacement becomes necessary fit only the correct liner see page 23 The build up of dust 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 8 Weldmatic 8mm amp 10mm Welding tip is free of obstructions such as spatter build up Ream out the tip bore with a suitable size oxy tip cleaner Replace the welding tip as it becomes worn Feed roll pressure is not excessive The pressure should be just sufficient to feed the wire evenly Excessive pressure will deform the electrode wire and make feeding more difficult Consumable wire spool holder rotates smoothly and that the braking action Is not excessive The spool should only have sufficient braking to prevent over run when the motor stops This also may be conveniently checked each time the wire is replenished Welding wire is straight and free of buckles or waviness To check remove 2 or 3 metres of wire from the spool Clamp one end in a vice or similar then holding the other end pull the wire out straight Look down the length of the wire any buckles will be obvious Buckled wire is extremely difficult to feed reliably and
10. 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 please read the Safe Practices section of this manual This will help to avoid possible injury due to misuse or improper welding applications Plastic Handle on Power Source Please note that the handle fitted to the Weldmatic 8mm and 10mm power sources Is intended for moving the equipment by hand only DO NOT use this handle for Suspending or mounting the power source in any other manner Safe practices when using welding equipment These notes are provided in the interests of improving operator safety They should be considered only as a basic guide to Safe Working Habits A full list of Standards pertaining to industry is available from the Standards Association of Australia also various State Electricity Authorities Departments of Labour and Industry or Mines Department and other Local Health or Safety Inspection Authorities may have additional requirements Australian Standard AS1674 2 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 fro
11. the side walls A bad weld is shown in Figure 5 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 vvirefeed speed and arc voltage to achieve a higher current weld setting ai Quality e Reliability e Performance Weldmatic 8mm amp 10mm Ns Fig 4 Good Weld Fig 6a Gas Shielded Solid Wires AA Fig 5 Bad Weld Gun Position For down hand fillet welding with gas shielded solid wires the gun is normally positioned as shown in Figure 6a with the nozzle end pointing in the direction of travel For down hand fillet welding with gasless flux cored wires the gun is normally positioned as shown in Figure 6b with the Fig 6b Gasless Flux Cored Wires nozzle end pointing away from the direction of travel referred to as dragging the weld Gasless flux cored wires should be operated with approximately 15mm of wire stick out from the welding contact tip as shown In Figure 6c AS Kx ANN SX IN Fig 6c VVire Stickout for Gasless VVelding Model Nos CP118 0 amp CP119 0 Iss A 07708 13 Operators Manual Duty Cycle The term duty cycle indicates the percentage welding time available at the rated output current for each 10 min period over 4 hours If the machine is operated at a reduced welding current a
12. NG ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY WIA IS EXCLUDED AND DISCLAIMED BY WIA Weldmatic 8mm amp 10mm Model Nos CP118 0 amp CP119 0 Iss A 07 08 25 Operators Manual Notes 26 Hai Quality e Reliability e Performance Notes
13. RCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at VVIAS option 1 repair or 2 replacement or where authorised in writing by WIA in appropriate cases 3 the reasonable cost of repair or replacement by an authorised WIA service agent or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense WIA s option of repair or replacement will be F O B Factory at Melrose Park Adelaide or F O B ata WIA authorised service facility as determined by WIA Therefore no compensation or reimbursement for transportation costs of any kind will be allowed EAA Quality e Reliability e Performance TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL WIA BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTEE OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDI
14. acturer their service agent or a similarly qualified person EAA Quality e Reliability e Performance 1 Introduction Gas Metal Arc Welding GMAW Is an arc welding process where a consumable wire is fed by motor driven feed rolls 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 both shielded by gas flow trom the gun or in the case of self shielded wires by gases generated by the wire core The process is very versatile in that by selection of the correct wire composition diameter and shielding gas it can be used for applications ranging from sheet metal to heavy plate and metals ranging from carbon steel to aluminium alloys The Weldmatic 8mm and Weldmatic 10mm have been designed to be used with consumable wires in the range trom 0 6mm solid to 1 2mm cored 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 GMAW is for welding Mild Steel In this application a Mild Steel solid consumable wire such as AUSTMIG ES6 Is used with a shielding gas of Carbon Dioxide or Argon mixed with Carbon Dioxide Alternatively Flux cored consumable wires are available in both gas shielded and gasless se
15. aluminium particular care must be taken with all aspects of shielding gas delivery and workpiece preparation in order to avoid weld porosity 12 Establishing a Weld Setting Once the consumable wire type wire size and shielding gas have been chosen the two variables that are adjusted in order to obtain a the desired weld setting are e Wirefeed speed e Welding arc voltage For each of the combinations of voltage control switch settings there Is a range of valid wirespeed settings The wirefeed speed determines the welding current increasing the speed increases the current and decreasing it decreases current The selected vvirefeed speed must be matched with sufficient arc voltage a speed increase 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 metal transfer occurring as a series of large droplets Important Do not operate the Voltage Control switches during welding The weld setting should be chosen to suit the application and 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 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
16. connections in the external welding circuit are clean and tight Problems may show as hot spots Work piece surface is not contaminated Water oil grease galvanising paint or oxide layers can severely disturb the welding arc and result in a poor weld Porosity in weld caused by lack of shielding gas Check that the correct gas flow rate has been set refer Section 7 Check for leaks in the gas hose Replace if leaking Check for leaks in gun cable assembly eg fractured gas hose broken or missing O rings Replace as required Check the gun nozzle is free from spatter and is firmly attached to the welding gun to ensure that no air is being drawn into the shielded area Weldmatic 8mm amp 10mm Model Nos CP118 0 amp CP119 0 Iss A 07 08 17 Operators Manual 10 Service Information The following information is intended for use by qualified service personnel When the unit is energised LETHAL VOLTAGES are present on the electrical and electronic components It is not intended that persons without suitable training and knowledge attempt to perform service tasks on the components of this welder 10 1 PWAOOSN Control Board Before removing the equipment cover ENSURE that the equipment is disconnected from the mains power supply When the equipment is energised LETHAL VOLTAGES are present on the electrical components enclosed Gas valve 30 Vac Pal P7 P11 P12
17. e 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 2 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 2 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 equipment is correctly connected and earthed If unsure have the equipment 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 If the supply cable is damaged it must be replaced by the manuf
18. e notified in writing within thirty 30 days of such defect or failure at which time WIA will provide instructions on the warranty claim procedures to be followed WIA shall honour warranty claims on warranted equipment in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or 18 months after the equipment date of manufacture whichever is the earlier 24 Parts and workmanship on Weldarc and Weldmatic equipment are covered for a period of 3 years except for gas regulator gun cable and consumables listed below Items replaced under original warranty are warranted for the remainder of the original equipment warranty or for a period of ninety 90 days whichever is the greater Gas regulator and gun cable assembly are warranted for 90 days VVIA s Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays or parts that fail due to normal wear 2 Equipment that has been modified by any party other than WIA or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment WIA PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMME
19. ead 3 Withdraw old liner trom the wirefeeder end Insert new liner and refit gun cable assembly to the wirefeeder 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 5 Refit head tip and nozzle Model Nos CP118 0 amp CP119 0 Iss A 07 08 23 Operators Manual 12 Warranty Information WARRANTY WIA Gold Shield 3 Year Warranty Effective 1st March 2005 At WIA we are serious about product quality Every new Weldmatic and Weldarc machine comes fully backed by the WIA Gold Shield 3 Year Warranty covering parts and workmanship so you can be guaranteed you re buying reliability and performance This limited warranty supersedes all previous WIA Welding Industries of Australia warranties and is exclusive with no other guarantees or warranties expressed or implied Limited Warranty Subject to the terms and conditions below WIA warrants to its original retail purchaser that new WIA equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by WIA THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below WIA will repair or replace any warranted parts or components that fail due to such defects in material or workmanship WIA must b
20. he Weldmatic 8mm and 10mm are factory fitted with a mains power supply cable with moulded 3 pin 15 Amp Single Phase plug Note If the Weldmatic 10mm is to be used at maximum output current and duty cycle an appropriate 20 Amp plug should be fitted by a qualified electrician The minimum capacity of the mains wiring and power outlet supplying a welder is selected according to the effective primary current of the equipment Refer to Specifications Section 3 for the relevant Effective Primary Current rating and recommended mains circuit breaker Note Due to normal variations of sensitivity the tripping time of some circuit breakers may limit the duty cycle available from the Weldmatic 8mm and 10mm A higher rated circuit breaker can be selected but the mains wiring capacity must be increased to suit The current rating of the mains wiring 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 supply terminals is gained by removing the power source side panels The replacement cable must be fitted and retained in the same manner as the original Fan on Demand The Weldmatic 8mm and 10mm feature fan on demand The cooling fan will only run when required to cool internal components When no longer required the fan will automatically stop Weldmatic 8mm
21. lete Item Part Description 1 W51 0 20 Fixing Cap 2 W50 0 27 Adapter Ring 3 WF001 21 Outlet Guide Tube Feed Rolls Part Description W51 0 5 0 6 0 8mm Solid Wire fitted W51 0 2 0 9 1 2mm Solid Wire W51 0 1 1 2 1 6mm Flux Cored Wire knurled W51 0 3 0 9 1 2mm Aluminium W5 1 0 4 0 8 1 0mm Solid Wire W51 0 49 0 8 0 9mm Flux Cored Wire knurled 22 EAA Quality e Reliability e Performance Weldmatic 8mm amp 10mm 11 3 Assembly and Parts List Gun and Cable Assembly Fig 12 BEQ1510AO7CE 180 amp Gun and Cable Assembly Item Part Description 1 BE4392 Nozzle Assembly 2 see Tips Contact Tip 3 BE4335 Head 4 BE4323 Cap 5 BEQT2 30 Body Tube 2 30 BEQT2 45 Body Tube 2 45 6 BE2620054 Switch Assembly includes lower handle 7 BE1880194 Handle Kit both halves includes screws 8 BE2520007 Cap Rigid Strain Relief 9 BE2520048 Spring Strain Relief 10 BE2520047 Strain Relief Euro 11 BE1199E Euro Direct Plug Kit inc 11a BE9165 Small O Ring 11b BE4421 Large O Ring 12 BE43015 Steel Liner 0 6 0 8mm BE43110 Steel Liner 0 9 1 2mm BE43115X Nylon Liner 0 9 1 2mm Tips Wire diameter Part 0 6mm BE7497 0 8mm BE7488 0 9mm BE7489 1 2mm BE7490 To replace liner Disconnect gun cable assembly at the Euro adaptor Remove nozzle 1 and h
22. lf shielding types Stainless steel and Aluminium can be welded with G M A W using the correct consumable wire and shielding gas The Weldmatic 8mm amp 10mm wirefeeder has been designed to feed a range of hard soft and flux cored wires for the GMAW process A compact motor with integral gear box is coupled to a two roll drive assembly forming the basic component of the wirefeeder The motor is controlled by an electronic speed control which provides speed regulations Weldmatic 8mm amp 10mm 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 Weldmatic 8mm package CP1 18 0 contains e Power Source CP118 2 e 3m gun and cable assembly 5m work lead e Argon mixed gas regulator e This operating manual CP118 40 The Weldmatic 10mm package CP119 0 contains e Power Source CP119 2 e 3m gun and cable assembly 5m work lead e Argon mixed gas regulator e This operating manual CP118 40 Note that accessory items are packaged inside the power source Model Nos CP118 0 amp CP119 0 Iss A 07 08 5 Operators Manual 3 Specifications Manufactured to Australian Standard AS1966 1 Rated to ISO 60974 1 Weldmatic 8mm Weldmatic 10mm Primary Voltage 240 Vac 50 60Hz 240 Vac 50 60Hz Rated Primary Current 15 Amps 18
23. m radiant energy and flying metal Replace the cover lens when broken pitted or spattered Recommended shade filter lens Pulsed Amps TIG MMAW MIG MIG 0 100 10 9 10 12 13 100 150 11 10 10 12 13 150 200 12 10 11 11 12 12 13 200 300 13 11 12 13 12 13 300 400 14 12 13 14 400 500 13 14 14 500 14 14 EAA Quality e Reliability e Performance Burn protection The welding arc is intense and visibly bright Its radiation can damage eyes penetrate light weight 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
24. ot switch the equipment off as the cooling tan will assist the resetting of the thermostat e f problem persists after the cool down period call your WIA service agent Power source has low weld output 1 Check all electrical connections in the welding current circuit including weld cable work clamp and gun cable assembly Circuit breaker trips during welding 1 Check the rating of the mains supply circuit breaker Refer to the Specifications on page 6 for the recommended circuit breaker rating Unsatisfactory Welding Performance and Results Erratic arc characteristics caused by poor wirefeed Erratic wirefeed is the MOST LIKELY cause of failure in all Gas Metal Arc Welding It should therefore be the first point checked when problems occur 1 Refer to the points in Wirefeed in Section 8 2 Check if the consumable wire is slipping in the drive rolls Replace the feed roll if it is the incorrect size or is worn 3 Check that gun cable liner is not too short and is fitted correctly Refer to Section 11 3 for fitting instructions ga Quality e Reliability e Performance Constant poor arc characteristics Check that the Correct polarity has been selected for work and weld cables refer Section 5 Shielding gas is correct for the consumable wire in use refer Section 7 Ensure that the work clamp is securely tightened onto the work piece so that good electrical contact is achieved All
25. ption Qty Weldmatic Weldmatic 8mm 10mm 1 WHLOO2 WHLOO2 Wheel Rubber Castor 2 2 VVHLOO3 VVHLOO3 Wheel Rubber Fixed 2 3 M0020 M0020 Ratchet Cap 1 4 CP110 10 1N CP110 10 1N Switch Coarse Fine 2 5 E0042 E0042 Switch Standby 1 6 E0016 E0016 Control Knob Small 3 7 W41 0 2 WA41 0 2 Hinge Set Right Hand 1 8 WA41 0 1 WA41 0 1 Hinge Set Left Hand 1 9 MZ208015 MZ208015 Handle 1 10 M0029 M0029 Control Knob Large 1 11 LSTO17 LSTO18 Sticker set 1 12 W29 1 20 W29 1 20 Slam Action Catch not shown 2 13 SA140 0 2 SA140 0 2 Socket Dinse 2 14 WGEC3 WGEC3 Plug Dinse 1 15 VVFO21 VVFO21 VVirefeed Assembly see page 18 1 16 E0024 E0024 Circuit Breaker 5A 17 AM133 3 AM133 3 R clip 1 18 AM177 AM177 Spool holder assembly 1 19 PVVAOOSN PVVAOOSN VVirefeed Control Pcb 1 20 E0022 E0022 Contactor 1 21 D0029 D0029 Rectifier 1 Not shown CP3 9 8 CP3 9 8 Thermostat included in rectifier 1 2P INDO12 INDO14 Inductance Assembly 1 23 TFM034 38 Welding Transformer Assembly Wired 1 Not shown CP104 16 2 CP104 16 2 Thermostat included in transformer 1 24 LO020 LO020 Control Transformer 1 25 FANOO4 Fan Assembly 1 26 MC66 0 8 CP106 0 3 Mains Lead and Plug 1 27 E0041 E0041 Gas valve 24 Vdc 1 Not shown R0028 R0028 Fan on Demand Thermistor 2 Model Nos CP118 0 amp CP119 0 Iss A 07 08 21 Operators Manual 11 2 Assembly and Parts List Wirefeed Fig 11 VVFO21 Wirefeed Assembly VVFO21 Wirefeed Assembly Comp
26. release the compression screw by swivelling it outwards This allows the top roller arm to spring to the open position The end of the welding wire can now be passed through the inlet guide over the bottom drive roller and into the output wire guide tube Check that the drive roll groove is correct for the wire in use The wire size is stamped adjacent to each groove The working groove is installed to the back Check also that the correct size contact tip Is fitted at the gun end Feed roller and tip details are shown later in this manual Return the top roller arm to the closed position and adjust the compression screw to provide sufficient clamping of the drive roll to achieve constant wirefeed Do not over tighten With the equipment energised operate the gun switch to feed wire through the gun cable Compression screw Top roller arm Inlet guide UJ VVeldmatic 8mm 8 10mm 6 Normal VVelding Sequence Weld Start Closing the welding gun switch initiates this sequence of events e The gas valve is energised and gas flow commences e The power source contactor is initiated Welding voltage is applied between the work piece and the consumable wire e The wire drive motor is energised e The wire touches the work piece and the arc Is established Weld End Releasing the gun switch initiates this sequence of events e The wire drive motor is de energised and is dynamically braked to a s
27. should be replaced Welding wire is free of surface rust Replace if rust is evident Model Nos CP118 0 amp CP119 0 Iss A 07708 15 Operators Manual 9 External Trouble Shooting If the following checks do not identify the fault condition the equipment should be returned to a WIA Service agent Phone 1300 300 884 for details of your nearest service agent Power source has no output and no wirefeed when gun switch is closed STANDBY switch is not illuminated 1 Check equipment is connected to a functional mains power outlet and OPERATE is selected Test outlet using a known working appliance STANDBY switch is illuminated 1 The machine circuit breaker may have tripped e Check that the wire is not fouled in the wirefeed machinery e Push the red button located inside the wirefeed enclosure to reset the circuit breaker 2 The gun switch circuit may be incomplete e Check the gun switch for continuity with an ohm meter when the switch is pressed Replace if faulty e Check the 2 pin receptacles in Euro adaptor are making contact with the mating pins from the gun Euro end 3 Power source may have overheated e The Weldmatic 8mm and 10mm welding power source incorporates an in built over temperature thermostat which will trip if the welding load exceeds the operating duty cycle The OVERLOAD light will be illuminated The thermostat will 16 reset automatically do n
28. top e The power source contactor is released e The gas valve is de energised and the flow of shielding gas ceases Working groove is fitted to the back Model Nos CP118 0 amp CP119 0 Iss A 07708 11 Operators 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 8mm and 10mm are e Mild Steel Argon 5 to 25 Carbon Dioxide e Aluminium Argon e 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 function 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 12 litres min In situations where drafts cannot be avoided it may be necessary to increase this rate up to 20 litres min 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 When welding
29. trol This control provides adjustment of the vvirefeed speed Rotating the dial in a clockwise direction will increase the vvirefeed speed thereby increasing the welding current 7 Control Circuit Breaker The machine control circuits are protected by a5 Amp circuit breaker located inside if necessary the circuit breaker can be reset by pressing the central red button 8 Gun Switch Control Three gun switch modes are available NORMAL Welder operates while the gun switch is closed welding ceases when the switch is opened Gun Switch Welding LATCH Welder operation is initiated by a close and release of the gun switch Welding continues until a second close and release action Gun Switch TI SPOT Welding is initiated by closing the gun switch The weld duration is controlled by the SPOT TIME setting gt lt Spot time 9 Standby switch When set to STANDBY the welder will not operate CAUTION Live parts exist on internal components and wiring when the machine is in STANDBY Before any work is undertaken on any internal parts ie accessed by removing machine covers the unit must be completely isolated from the mains supply 10 Euro Gun Cable Connector 11 Positive Welding Output Terminal 12 Negative Welding Output Terminal EAA Quality e Reliability e Performance 5 Installation Connection to Electrical Mains Power Supply T
30. 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 Weldmatic 8mm amp 10mm 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 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
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